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Applications for Compressed Air Operated Vortex Tubes. Compressed air-operated vortex tubes have been commercialized since 1960. These devices take compressed air at a given inlet temperature. And split the flow up into a hot (usually waste) and a very cold (usable) air stream used for cooling.

The significant temperature drop improves. When an application requires such low values, sub-zero temperatures can be produced. While the cost of compressed air is still a concern in their use, specific applications make them viable. Pay attention when these application advantages outweigh the energy costs.

Consider the following

Cooling CCTV cameras, sensors, small control boxes in inkjet printers, and other small devices with vortex tubes or packaged versions like Panel Coolers is more economical than using cooling water alone or compressed air alone. Some other alternatives can even be more costly or challenging.The cold air produced by the vortex tube means less compressed air is required to use only compressed air. Water causes scaling issues because of the high heat exposure and circulation through small water lines.

Fans to cool usually cannot work well because of the hot and often dirty environment. Using heat pipes requires a cool ambient to be effective and limits the ability to cool. A similar situation exists with thermoelectric cooling.

Cabinet Enclosure Cooling or Panel Cooling (Electrical and electronic air conditioners) is ideal for Panel Cooling under certain conditions over regular air conditioners, fans, and other alternatives like water and thermoelectric.Regular air conditioners generally use less energy, but you must address refrigerant replacement over time, change filters regularly, and deal with condensation. Vortex tube-operated coolers are dependent only on compressed air temperature for cooling effect.

As a general guide, the hotter and dirtier the environment, the greater the benefit of vortex tube technology. This is because the worse the environment, the higher the maintenance costs, especially filter replacement, which is not only a filter cost but can also be an ever-increasing disposal cost.

This can offset any increased energy costs.For obvious reasons, a dirty environment is not conducive to the use of fans. They will clog quickly and stop workingA hot environment aggravates the problem and works against using thermoelectric technology. Water cooling introduces potential scaling issues and other maintenance costs.

Vortex tube-operated panel coolers are essentially maintenance-free, produce no condensate to deal with, and keep the control panel under slight positive pressure to keep out any nasty factory environment.

This is very advantageous if maintenance is complex because of panel location, whether in a hard-to-reach factory location or in a geographical area that lacks the necessary maintenance personnel.

Manufacturers typically package vortex tubes with a magnet and flexible hose to direct cold air. Especially in dry machining applications involving ceramics, glass, plastic, and materials like titanium.This can decrease machine time and improve the quality of the machining.

There has been an attempt to move away from liquid cooling as much as possible for environmental and safety reasons, which continues today. However, there are challenges as liquid cooling helps remove debris, and tooling material requirements can also change.

Using vortex tubes to chill liquid used for mist cooing also provides some lubrication when needed, such as in deep-hole drilling, and reduces the lubricant needed by as much as 20%.

Vortex tubes are perfect for other spot cooling applications.. Such as cooling hot melt adhesives, welds, soldering points, and gas samples. Because of their compact design, small footprint, no maintenance, and low capital cost.

While the commonly available vortex tubes are similar in design. Which has not changed for decades, companies such as Nex Flow are developing new, more efficient versions.  Providing the potential for greatly expanded use.

For assistance in using vortex tube technology, Nex Flow can help.

Blow hard or blow soft? That is an important question to answer based on your application needs. Cleaning and drying applications involve either wiping or using compressed air or blowers.

The contact between the material and the product being wiped often requires high maintenance for wiping, and one often dismisses it if the part is sensitive.

The alternatives are using either blower air or compressed air. Blowers are larger, have higher capital costs, are noisier, need more space, and require higher maintenance. They also have limited force, which limits their use. However, they offer energy savings in many cases, especially with continuous use.

Compressed are is popular because of a smaller footprint for the item doing the air blow off, less maintenance, much less capital cost, and greater force provided. Developers have created many options to reduce the added energy cost of using compressed air.

The first option involves on-off control and using the air only when needed. This is a huge advantage when the need is intermittent. When combined with the use of engineered air nozzles and other flow amplification products that primarily use the Coanda effect, energy use can even approach that of blowers in some cases, without the negatives.

But the application itself can determine the required force level—for example, whether a blower’s force suffices. Two often overlooked factors come into play when deciding what to use.

These factors are as follows

• Difficulty to dislodge whatever needs to be removed from the target surface
• Distance from the blow off to the surface

There is often a misconception that the more difficult it is to remove something from a surface, that more force can achieve it. It is simply not true. The material to be removed may be stocky, surface tension very high so just difficult to remove, or it could be a static charge holing the debris to the surface which can have a strong glue effect.

When using a blow off, the effective distance for force decreases very rapidly unless the blow off device produces laminar flow. Using a blow off with turbulent flow requires increasing the pressure to achieve more force at a distance, which consumes more energy. Engineered blow off is usually laminar and will therefore work at a greater distance. This explains why engineered air nozzle technologies are used; they work and save energy.

Pulsing blow off can be beneficial in difficult to remove materials if they are sticking due to “stickiness”. The pulse causes a scrubbing action which can then help in removing this debris. It can work for fine dust as an example. Pulse valves or devices that mimic a pulse action such as “scrub nozzles” which are rotating nozzles. Care must be taken if using pulse valves. Although they often claim savings up to 50%, in reality they average more like 25% but can even be negligible unless properly installed. Installation needs to take into consideration pressure loss during the pulse action. If a pulse valve is combined with an engineered (flow amplifying) air nozzle, this may extend the distance but, with less pressure. The effective distance, as a result, can be significantly less when pulsed.

Blow Hard or Blow Soft?

Any pulsed device usually needs to be closer to the target surface.If one can accomplish that, it can prove very effective in cleaning.Pulsing through a (flow-amplifying) air nozzle may extend the distance to any debris stuck inside a wire mesh or rough surface but pressure drop from the pulsing can limit that effective distance.

If materials are sticky due to static alone, combining a static eliminator with an engineered blow-off can be very effective, even at some distance from the target. You still need to take care regarding distance, as the rate of the static removal effect decreases the further you are from the ion-generating device, whether or not air is behind it. Beware of dubious claims about removing a static charge at 20 feet away.

Combining a pulsing nozzle with a static removal device can be very effective for removing difficult debris from materials such as plastic, where both the material’s stickiness and static can hinder cleaning. In these applications, you may still need to be close to the target surface for the pulse action to work.

Optimizing energy use is the last resort when addressing any drying or cleaning application. Very often, considering these alternatives can keep every cost low. Be aware of the target distance and the materials you need to remove from the target product. Instead of just increasing power usage, explore more effective approaches.

Compressed air-operated air knives are popular for blow-off, cleaning, drying, and even cooling applications. They replace pipes with holes and rows of air nozzles.

When properly sized and installed, they can reduce overall air consumption, reduce noise, and give a continuous and uninterrupted blow-off and cleaning curtain long its length.

As simple as an air knife looks, it is actually a precision-made instrument, and certain characteristics identify a well-produced air knife versus a mediocre design.

Performance comes first, defined by the efficiency and quality of the air output.

You can define efficiency as the airflow’s force (or velocity) divided by the air consumed (SCFM or SLPM). Most air knives tend to be relatively the same in terms of force/consumption, but the more efficient designs will give the highest force at a lower input pressure.

For example, compared to two other significant manufacturers, the Nex Flow® X-Stream® Air Blade Air Knife produces the same force at the same air consumption with the inlet at 60 PSIG compared to the others at 80 PSIG.

At such a significantly lower pressure requirement, one can potentially realize additional energy savings because producing 60 PSIG takes much less energy than producing 80 PSIG.

Another thing to listen for is the noise level between different makes of air knives. Low exhaust noise is a qualitative indicator of efficiency. The lower the noise, the greater the energy use efficiency.

The quality of performance depends on how evenly the flow remains over its length through a wide range of pressure inputs.An even flow across its size is generally the preferred result for applications instead of a design that may spike in the middle. A poorly designed air knife indicates a lack of understanding of the aerodynamics needed for the technology.

Then, there are obvious factors to consider, such as the construction of the air knife and its parts.

Most air knife designs use a shim to maintain the air gap (where the compressed air exits). People prefer metal shims over plastic shims because they last longer.Even metal shims can wear out over time especially if the air supply is not clean and dry. Plastic shims wear out much more quickly, requiring more maintenance for replacement, and they are, of course, cheaper to produce.

You can also machine the gap, and it is important to machine the gap evenly.

The material used in the body of the air knife may be aluminum, stainless, and, in some cases, plastic.

Aluminum air knives “should” be anodized. If you use aluminum air knives that are not anodized in a factory environment, the condition of the aluminum will deteriorate rapidly. You should not pay a premium for non-anodized aluminum products.

An excuse sometimes provided by suppliers who do not anodize is that it negatively affects the airflow. That is only true if the quality of manufacturing cannot be maintained. It is not an issue if produced well, just a valid cost.

When an air knife is assembled, the screws should be evenly torqued across the length and assembled according to instructions. An air knife should also have adequate mounting options to avoid the need to take them apart to mount. Nex Flow units have mounting holes on all their air knife designs.

Finally, good instructions and service are important. Nex Flow maintains a well-supported global supply chain.

Air Knives are a great product but vary widely in design and quality so choose your brand carefully.

Good Compressed Air Operated Air Knife, important things to know.

Hydraulics and or pneumatics are essential parts of various industries. They are critical to the performance of several types of tasks. Experts project both for continued worldwide growth well into the decade.

Hydraulics utilize a pressurized incompressible hydraulic fluid to produce and transmit a force to initiate a mechanical process, usually through cylinders. In the majority of cases, the fluid is oil. The system multiplies the applied force as the liquid travels through it, creating up to nine times more force than the initial applied force.

Pneumatics uses compressed air, produced by air compressors and transmitted via pressurized air lines. It also transmits a force and initiates a mechanical process through cylinders, and can directly apply to a target for blow-off, drying, cleaning, and cooling, either directly or through other devices.

Valves regulate the flow of air. Some forms of pneumatics inject inert gases into the process for specialized operations.

Benefits of Hydraulics:

• Easy to control
• High Force
• Constant and consistent force
• Few moving parts so relatively easy to maintain and simple to use.
• Relatively safe

Applications include hydraulic lifts, brakes, and applications in heavy industry and mining.

Benefits of Pneumatics:

• Pneumatic systems are often 50% of the cost of hydraulic systems
• Efficient when the air distribution systems are properly cared for to eliminate any complications with internal parts.
• Low maintenance and long life with pneumatic actuators.
• When power must be relayed over long distances, pneumatic systems are superior.
• Pneumatic devices are air-based with less complicated and compact designs and generally lower cost than hydraulic parts

Deciding to use a Hydraulic or a Pneumatic System

One type of system is generally suited well toward specific functions with a wide range where both can be used in between

Advantages of Hydraulics

• Safe and easy to maintain with fewer moving parts
• Fast Response time and more power (force)
• Liquid does not absorb supplied energy ie, incompressible
• Easily controlled

Disadvantages of Hydraulics

• Poor resistance to working fluid pollution, so fluid must be well-maintained
• Sensitive to temperature changes as fluid can be affected
• Hidden danger of leakage and environmental concerns, which is an ever-growing issue.
• Difficult for manufacturing and high in cost
• Not suitable for long-distance transmission.
• Possible fire hazard if not properly designed and if has inadequate safety protocols

Advantages of Pneumatics

• Uses abundant air
• The compressibility of air allows for storage
• Simple, lower construction costs, and easy to handle.
• Pressure and force can be controlled to a high level.
• Low Maintenance
• Explosion-proof as air is not explosive
• Low cost, simpler designs, and more compact designs
• Fire-proof as air does not burn

Disadvantages of Pneumatics

• Knowledge – there is a huge gap between knowledge about pneumatics compared to knowledge about hydraulics
• Limited force and power
• Due to its ability to transmit power over long distances, extra care is needed to keep the compressed air supply in working order.
• Generally high energy cost

Factors that Effect What to Choose?

Load or force – When a load is only a few pounds, pneumatics are a more practical choice since the force of hydraulics is unnecessary. But if it is high, you have little choice but to use hydraulics.

Cost – Pneumatics can operate from a single centralized compressor or group of compressors that can run a whole facility. This configuration is significantly lower in cost than hydraulic systems with machine-by-machine pumps and motors to maintain and repair.

Durability – Pneumatic systems are highly durable and seldom need repair. Even when they may fail gradually or leak air, they can still function. In the case of leaks, pneumatic systems, unlike hydraulic systems, are more environmentally friendly because they leak air instead of oil, allowing repairs to be scheduled without causing production downtime.

Speed – The wide use of pneumatic systems is found in factory automation, packaging, and applications where speed is essential and loads are low. The speed of pneumatic systems is high just because of the more compact and simpler designs.

Hygiene – Pneumatic systems win out over hydraulics in the field of hygiene, as air can only leak out of your system. Pneumatic systems are generally favored by environmentally conscious companies or those contemplating greener manufacturing practices.

This is an increasing factor when either pneumatics or hydraulics can be used. Pneumatics for a clean room, a pharmaceutical laboratory, or the food and beverage industry is universal.

Energy Cost

Energy cost is another important consideration. Both systems usually require an input of electrical power to drive them. A pneumatic system needs a compressor to continuously run to provide compressed air.

The air supply in a pneumatic system cannot be recycled and requires constant replenishment, so energy consumption in this respect may be high.

Air leakage due to system wear and tear, lack of care in the replacement of worn parts, and pressure loss with the incorrect choice of fittings, filters, etc, also wastes energy in the system. However, while hydraulics require energy to operate, they can become more energy efficient in the long run if properly filtered and maintained.

But in both processes, technological improvements and preventative maintenance greatly affect the real energy cost. In both cases, a poorly maintained system will use more energy. It is conceivable that a well-maintained pneumatic system will be more energy efficient than a poorly maintained hydraulic system.

The comparison can be even more complex when considering replacement parts costs much lower with pneumatics.

Maintenance Cost

Companies too often focus solely on energy costs, neglecting the intertwined maintenance costs. Pneumatic systems, being cleaner and simpler, typically require only a regular schedule of inspection and preventive maintenance. Tasks like checking seals and preventing air leaks suffice to maintain their operation.

In contrast, hydraulic systems frequently grapple with corrosion as their primary challenge. Unless made from non-corrosive materials like galvanized steel, these systems demand regular monitoring to evaluate the impact of the fluid medium on the pipes.

Furthermore, replacement hoses and parts for hydraulic systems tend to be more expensive.

Safety – Pneumatics is undoubtedly the safer option. Compressed air leakage will not cause contamination, does not generally pose a fire risk, and won’t explode. However, escaping high-pressure air through mechanical failure may cause physical injury.

Hydraulic fluids are always at risk of potentially dangerous leaks. Even water can cause damage if it’s hot enough to scald. The fluid media may be poisonous and may be combustible, requiring special safety precautions.

Eventually, one must drain and dispose of used oil or fluids, a cost that continues to grow.

Complexity – Hydraulic systems typically have fewer moving parts but rely on complex engineering that requires a system of valves and hoses, a pump powered by an external energy source, and a tank for storing the liquid medium.

Pneumatic system designs also typically feature simplicity and operate at much lower pressure, allowing for the use of cheaper and less complex materials for their parts. Compressed air is not corrosive or combustible, much less of a safety hazard.

Technological advances have increased the variety of uses for pneumatic systems, with miniaturization and new materials helping to reduce weight as well as bulk and with technologies to improve the efficiency of compressors and even air nozzles and devices used for cooling, drying, and cleaning and conveying.

Initial Cost – Often, whether a project is even started can depend on the upfront cost. Typically, a hydraulic system will have a much higher initial cost than a pneumatic system.

Final Thoughts

For low-scale engineering and mechanical tasks, pneumatic devices are the best choice, whereas hydraulic systems excel in applications needing higher force and heavy lifting. These are the guidelines for extreme uses. When the choice falls between both systems, it boils down to which factors are most important to the decision makers involved.

 Factors Affecting the Performance of Compressed Air for Blowing and Drying

Compressed air is a versatile and widely used resource in various industrial processes, including blowing and drying applications. Several key factors can greatly influence its convenience and efficiency.

Backpressure

Backpressure refers to the resistance that compressed air encounters as it flows through the system to the point of use. High backpressure can significantly affect performance by reducing the airflow and pressure available for blowing or drying. It results in increased energy consumption and longer cycle times. Frequently, installers fit a blow-off product, like an air knife, with a connecting tube, hose, or piping. However, that is too small in diameter or too long. This results in excessive pressure drop and complaints about lack of performance or non-performance. Opening the “gap” on the blow off to consume more air actually makes it worse as it only increases pressure drop. The first thing one should check for lack of performance is the connecting lines to the product.

Distance from Air Compressor to Point of Use

The distance between the air compressor and the point of use is another critical factor. As air travels through pipes and hoses, friction and pressure drop occur. Longer distances can lead to decreased airflow and pressure, impacting the efficiency of blowing and drying processes. Along the way to the point of use, if far, uses up energy and it is important to ensure there is adequate airflow and pressure by the time it reaches the point of use.

Leaks in the System

Even small leaks in a compressed air system can have a significant impact on performance. Leaks not only waste energy but also reduce the available airflow and pressure at the point of use. Regular maintenance and leak detection programs are essential to ensure optimal system performance. Addressing leaks promptly can lead to energy savings and improved efficiency. Not only the piping can cause issues, but connectors and accessories in the system may also have leaks, especially near the point of use. One should check these to ensure there are no leaks.

Dirt in the System

Dirt, dust, and contaminants in the compressed air system can clog, and reduce or otherwise negatively affect the performance of the blow-off product. Air knives for example can have a spec of dirt clog a small area at the air outlet causing uneven flow.

Implementing proper filtration at the point of use is crucial to keeping the system clean. Filters and separators should be regularly inspected and replaced to prevent dirt buildup, ensuring that the compressed air remains clean and adequate for blowing and drying applications.

Compressed Air Capacity

The capacity of the compressed air system directly affects its performance. If the demand for blowing and drying exceeds the system’s capacity, it can lead to reduced airflow and pressure at the point of use. To optimize performance, it is essential to assess the specific requirements of your application and ensure that the compressor and storage capacity can meet those demands. Upgrading the compressor or adding storage can be necessary in cases of increased demand. It is all too often a blow-off system is installed and only after the fact, there is a realization that there is not enough capacity. Before considering any application, there should be a clear understanding of how much airflow is available. Having said that, this also creates an opportunity to see where engineered blow-off products can reduce compressed used inefficiently and potentially reduce energy use.

Balance of Compressed Air Usage

Balancing the use of compressed air among multiple applications is critical for maintaining consistent performance. If one application consumes a significant portion of the available compressed air, it can affect others, leading to reduced efficiency. Implementing pressure regulators and flow control devices can help ensure that each application receives the necessary airflow and pressure, optimizing overall performance. The air will always travel the least resistant path so if blow-off applications are spread out, this should be kept in mind.

Compressed Air Can Be Stored

Using sensors and solenoid valves or other process valves can lead to significant energy savings in many blow-off and drying applications by activating the compressed air only when necessary. Specifically, intermittent blow-off applications tend to prefer compressed air over blowers and electric motors due to the convenience of storing compressed air. When deciding on a system, intermittence should be a consideration in estimating overall cost. Any system for blow-off or drying can be made dramatically more efficient utilizing this ability to store the energy and use only on demand.

Final Thoughts

Compressed air is a valuable resource for blowing and drying applications. However, its performance can be significantly affected by various as outlined above. By addressing these factors, industries can reduce energy consumption, improve productivity, and achieve better results in their processes. Nex Flow offers consultation services to assist in optimizing the use of compressed air for blow-off, cleaning, drying and cooling.

Pulsing of Compressed Air for Surface Cleaning Pros and Cons

In various industrial and manufacturing processes, workers commonly use compressed air to clean surfaces. This method efficiently removes dust, debris, and contaminants, but the way they apply it can significantly affect its effectiveness. Pulsing compressed air is useful in many applications. This article will explore when to pulse compressed air for cleaning surfaces and examine the pros and cons of this method.

When to Pulse Compressed Air for Surface Cleaning

• Periodic Cleaning Needs: Compressed air pulsing is particularly beneficial when surfaces require periodic cleaning. This is often the case in manufacturing facilities where equipment and machinery accumulate dust and particles over time. By pulsing compressed air at regular intervals, you can maintain a cleaner environment and prevent build-up that could lead to performance issues or product contamination. This can be achieved easily using sensors, timers and solenoid valves for simple on-off control as required.
• Sensitive Surfaces: Fast pulsing of compressed air is an ideal choice when dealing with delicate or sensitive surfaces. Some surfaces, such as electronic components or precision items, often cannot withstand the continuous force of high-pressure air. Pulsing allows for a gentler cleaning action, reducing the risk of damage. For such applications a pulsed nozzle such as the Nex Flow Air Scrub Nozzle can provide that gentler force with the scrubbing caused by its pulsing operation.
• Removal of Loose Particles: When the primary objective is to remove loose particles or dust from a surface where the dirt is lodged or stuck, pulsing compressed air can be highly effective. In fact, just straight airflow often does little to remove stuck particulate. The intermittent bursts of air dislodge and propel particles away from the surface, leaving it clean and debris-free. The Air Scrub nozzle or special process valve systems that pulse the air can be highly effective in these applications.

Advantages of Pulsing Compressed Air

• Energy Efficiency: One of the significant advantages of pulsing compressed air for surface cleaning is its energy efficiency. Delivering short bursts of air reduces air consumption compared to continuous airflow, resulting in lower energy costs. Savings can vary depending on the installation details.
• Reduced Noise: Pulsed air systems are generally quieter than continuous systems. This offers an advantage in settings where minimizing noise pollution is necessary, such as in office environments or areas near residential neighborhoods.. However, that also can depend on the device that does the pulsing.
• Extended Equipment Life: Pulsing compressed air is gentler on equipment and reduces wear and tear compared to continuous blasting. This extends the life of cleaning equipment and reduces maintenance and replacement costs.
• Improved Cleaning Precision: Pulsing allows for better control and precision in cleaning, making it suitable for applications where accuracy is crucial. Operators can adjust the pulse frequency and duration to meet specific cleaning requirements if special pulse valves and assemblies are used.

Disadvantages of Pulsing Compressed Air

• Potential Residue: Pulsing may not be as effective at removing stubborn or adhesive contaminants as continuous air flows despite being able to dislodge stuck particulates. Some residue may remain on the surface, necessitating additional cleaning methods.
• Limited Cleaning Speed: Pulsing compressed air may be slower in cleaning large surfaces than continuous airflow systems. In time-sensitive applications, this reduced cleaning speed may not be ideal. As line speeds increase, the required pulse frequency must also increase to ensure all surfaces are adequately addressed. But higher speeds also require careful design to deal with the higher frequencies.
• Initial Investment: Implementing a pulsed compressed air system may require an initial investment in specialized equipment and controls. Decision-makers must consider this cost in the decision-making process.

Final Thoughts

Pulsing compressed air for surface cleaning can be a highly effective method. Offering numerous advantages such as energy efficiency, reduced noise, and extended equipment life. It is particularly suitable for periodic cleaning needs and delicate surfaces. However, it may not be the best choice for applications requiring rapid cleaning or removing stubborn contaminants. When deciding whether to use pulsing compressed air, carefully assess your cleaning requirements and weigh the pros and cons to determine whether this method fits your specific application.

.Compressed Air Systems and Performance Efficiency

Pressure drop is a crucial aspect of compressed-air technology that is often overlooked. It is defined as the reduction in air pressure from the compressor discharge to the point of use. And is caused by resistance encountered by the compressed air as it moves through the system’s components. This includes pipes, valves, and fittings. Even a minor pressure drop can significantly reduce the system’s efficiency and operational cost. If achieving a high-performance compressed air system is the goal. Then it is essential to have a thorough understanding of pressure drop and its management.

The impact of pressure drop goes beyond technical glitches, affecting the system’s efficiency and operational costs. A higher pressure drop necessitates the compressor to work harder to maintain the required pressure. Leading to increased energy consumption and a larger carbon footprint. Additionally, a significant pressure drop can negatively impact the functioning of air-operated equipment, leading to inferior product quality and reduced productivity.

Compressed Air Systems and Performance Efficiency

Pressure drop particularly affects the performance of engineered air nozzles and air knives used for blow off and cleaning applications. Pressure drop particularly affects them.

These specialized tools require a steady, precise pressure to operate optimally. A pressure drop can lead to inadequate performance, resulting in less effective blow off, cleaning, or cooling applications. For instance, an air knife used to strip away excess liquid or debris may fall short, leaving residues that could compromise the quality of the final product or the efficiency of subsequent processes.

Prevention and consistent monitoring are the two-pronged approach to addressing pressure drop. Prevention involves designing a system that minimizes resistance by employing larger diameter pipes, minimizing bends in the piping, and opting for low-resistance components. Regular maintenance to eliminate leaks and blockages further reduces pressure drop and prolongs the system’s lifespan. Monitoring via pressure gauges, flow meters, and real-time monitoring equipment can unveil and help rectify pressure drop issues, ensuring the engineered air nozzles and air knives perform as intended.

In conclusion, pressure drop in compressed air systems is a critical factor that warrants meticulous attention. By understanding its implications and adopting a vigilant approach towards prevention and monitoring, operators can significantly improve the efficiency and reliability of compressed air systems. Timely addressing of pressure drop issues translates to energy savings and a more sustainable and productive operational environment, ensuring that engineered air nozzles and air knives function optimally to uphold the highest standards of quality and efficiency.

Understanding NEMA Type 4-4X Panel Coolers for Cabinet Enclosures and the right time to utilize them.

NEMA Type 4 enclosures, equivalent to IP 66 in Europe, resist water sprays and are dust-proof. The 4X version also resists corrosion. Electrical enclosures in corrosive or weathered environments need this standard. NEMA Type 4 or 4-4X rated enclosures require equivalent cooling systems.

Some NEMA Type 4 coolers use an aluminum cover and a stainless steel vortex tube. Others use different metals. Frequent wash downs can corrode the large cover, especially if not anodized. This corrosion comes from residual water. NEMA type 4X units, often made of stainless steel, are more reliable long-term.

NEMA Type 4-4X Requirements

A NEMA Type 4-4X cooler is waterproof, but you shouldn’t submerge it. It must resist heavy water sprays without water entry. UL and ULC rigorously test this for certification. Ensure the cooler has proper approval.

NEMA type 4X coolers undergo rigorous corrosion tests. They face 1200 hours in moist air with carbon dioxide and sulfur dioxide. They also endure 800 hours of salt spray tests. These vortex operated cabinet enclosure coolers, must be dust proof and ice-damage resistant. Often, manufacturers use stainless steel for these devices. Stainless steel best resists corrosion and weathering for the NEMA rating.

Applications for NEMA 4X Enclosures

The range of applications for NEMA Type 4X coolers are many, environments with aggressive conditions to the ability to retain their cosmetic look and maintain functionality under all conditions to which they may be subject. The resistance to corrosion, water sprays and adverse weathering represent three important applications for NEMA Type 4X enclosures.

Corrosive Substances in the Atmosphere

When corrosive gases and vapors are present, NEMA Type 4X enclosures protect electrical equipment and internal devices from contamination and harm. Vortex-operated coolers in particular keep control panels at a slightly positive pressure to keep out contaminated air. Industry examples include wastewater facilities, and factories handling corrosive chemicals.

Corrosion tests may only include certain conditions. Therefore the resistance of seals and the enclosure cooler materials of construction to particularly aggressive chemicals should be verified before using. A NEMA Type 4X enclosure is not suitable for use in hazardous areas where explosive vapors may exist. Such units are of a different design.

Wash Down and Heavy Splashing Areas

A NEMA Type 4X enclosure is ideal in food processing operations when equipment is subject to being washed down with either water or chemical solutions to maintain hygiene standards. It’s also applicable to other facilities that use water sprays like dairies and vehicle cleaning services, and anywhere high-pressure cleaning equipment may be utilized.

In some manufacturing areas, if there is a risk of accidental splashing and contamination of equipment from fluids used during processing, such coolers are ideal. One example is for the pulp preparation locations in paper mills. NEMA Type 4X vortex-tube-operated coolers are especially suitable for use in marine environments where equipment may be exposed to salt water. In marine environments, 316 or 316L stainless steel should be the main construction of Panel Coolers.

All-Weather Outdoor Locations

NEMA Type 4 Panel Coolers are weatherproof and fit for outdoors. However, NEMA Type 3R versions are often cheaper and also outdoor-approved. Specifically, stainless steel NEMA Type 3R or 4X enclosures work well in dusty, wind-abrasive areas. They’re also ideal in hot, humid places like coasts where mild steel corrodes quickly. Using 316L stainless steel designates it as a NEMA Type 4X unit.

Nex Flow manufactures all of their Panel Coolers in stainless steel to offer the best durability for any NEMA Type application: NEMA Type 12 (IP 54), NEMA Type 3R (IP 14) and NEMA Type 4-4x (IP 66).

Pulsed Compressed Air and Modern Valve Technologies for Today’s Applications

Pulsed Compressed Air & Modern Valve. Technologies. Compressed air serves many industrial uses, like blow-off, cooling, and cleaning. Solenoid valves once introduced the method of pulsing air. This means releasing it in short bursts instead of a continuous flow. This approach has both pros and cons.

Benefits of Pulsed Compressed Air:

• Energy Savings: Pulsing uses less air, saving energy costs.
• Effective Cleaning: Bursts can shake off particles better.
• Reduced Noise: Pulsing is quieter.
• Extended Equipment Life: Less use means less wear.
• Less Moisture: Fewer moisture problems.
• Safety: It exposes us to less force.

Drawbacks of Pulsed Compressed Air:

• Cleaning Concerns: Pulsing might miss some debris.
• Control Issues: It might need advanced controls.
• Response Delays: It might not deliver force immediately.
• Possible Wear: Starting and stopping might wear it out.
• System Sensitivity: Pressure changes can be tricky.
• Air Quality: There’s a contamination risk.

Often, incorrect installation happens due to insufficient knowledge. Consequently, this can lead to issues like reduced force or unexpected air consumption. These challenges, in turn, could slow the adoption of pulsing. Moreover, while many focus on air savings, it’s worth noting that other methods can offer similar benefits. Therefore, pulsing should be chosen based on its advantage over constant flow. However, in the right situation, pulsing offers several distinct benefits.

Beyond just the method of air delivery, there are innovations. Traditional tools like solenoid valves now have advanced alternatives.

Modern Valves for Pulse Applications:

• Piezoelectric Valves:
  • Pros: Quick switches, energy-efficient, and durable.
  • Cons: Pricier and more complex.
• Proportional Valves:
  • Pros: Precise control and versatile.
  • Cons: Complex and costly.
• Fast Switching Valves:
  • Pros: Swift and reliable.
  • Cons: Not as versatile.
• Smart Valves with Sensors:
  • Pros: Real-time data and improved control.
  • Cons: Complex and more expensive.
• Magnetic Valves:
  • Pros: Durable and quick responses.
  • Cons: Uses power continuously.

These new tools tackle the maintenance issues of old valves. Also, they can be more expensive initially. Thus, the key is to ensure pulsing is productive for your needs. Expert advice, like from Nex Flow, can help.

Pulsed Compressed Air and Modern Valve Technologies Conclusion:

As industries grow, so do their tools and methods. Using pulsed compressed air and new valve technologies highlights the push for efficiency and safety. Both the pulsing method and valve choice aim for best results with fewer resources.

Decision-makers must weigh these methods and technologies against their specific needs. This exciting crossroad of innovation and application offers many solutions.

Nex Flow provides consultations to help you find the best approach for your compressed air needs.

The NEW NEX FLOW Compressed Air Scrub Nozzle simulates pulsing air to clean and dry tough surfaces.

Historically, people have used Pulsing Compressed Air since solenoid valves came into existence. And it offers specific advantages over continuous compressed air:

• Energy Savings: Pulsing consumes less air than continuous blowing.
• More Effective Cleaning: Pulsating action dislodges particles better. Intermittent bursts produce rapid force changes, breaking static or adhesive forces on particles.

Unfortunately, old-style solenoid valves with Pulsing Compressed Air cause pressure loss and have high maintenance costs. This led to the creation of more efficient, long-lasting process valves. Nex Flow offers these valves. They have benefits and drawbacks. Also, they’re more costly and need precise installation. Assess them per application.

Interestingly, the Air Scrub Nozzle pulses without a pulse valve. The nozzle has a flexible tube ending. It rotates from the compressed air action through a patented connection. This reduces wear on the assembly. The rotation mimics pulsing, giving the “scrubbing” effect for cleaning or drying. The nozzle consumes little air. The rotation assembly lasts 3000 hours. After that, it needs a simple, affordable replacement.

However, this nozzle doesn’t amplify, so place it close to the target. The turbulent air from rotation creates a pulse action. It cleans and dries with less force. You can often use it on products not securely fixed.

It doesn’t replace applications where pulse process valves fit better. However, it’s an effective, affordable solution when you need scrubbing over high flow and force.

See our product: X-Stream® Air Scrub Nozzle

The NEX FLOW Compressed Air Scrub Nozzle

Is a game-changer in surface care. Using a unique pulsing action, it efficiently cleans and dries challenging surfaces. Unlike traditional solenoid valves, this nozzle operates without a pulse valve, reducing wear and maintenance. Its innovative design ensures minimal air consumption and a lasting rotation assembly. Ideal for close-range applications, it offers an affordable yet effective alternative for surface scrubbing needs.

Hydraulics Pneumatics or Electrical? 

Great question. Let’s look at Pneumatics first.

Pneumatics is more cost-effective than Hydraulics as air is free and can useable generally n flammable environments. Pneumatics offers more power in a smaller and lighter unit compared to most other technology systems, as well as being a much cleaner technology.

Hydraulics Pneumatics or Electrical? Now a bit about Hydraulics.

Hydraulics is generally more cost-effective than electrical systems as the fluid absorbs excessive force, which means fewer equipment damage threats.

Hydraulics, Pneumatics or Electrical? Last but not least Electric.

Some prefer electric drive over the pneumatic and hydraulic system, as electric drive actuators generally have better point-of-interest accuracy and repeatability than an equivalent pneumatic or hydraulic actuator.

The other advantage of electric actuators is the operating cost, but the capital cost can be high.

However, pneumatic actuators use compressed air, which is more expensive and less efficient to produce.

Hydraulic actuators are suitable for high-force applications, whereas pneumatic actuators can be for extreme temperature applications.

They can keep constant force and torque.

But pneumatic actuators are cost-effective and require minimum maintenance.

An apparent difference between a hydraulic and an electrical actuator is how each one derives its power.

Like pneumatics, hydraulic actuators comprise pistons that move inside a hollow cylinder. Incompressible liquid coming from a pump moves the cylinder. As the pressure increases, the cylinder is likewise moved along the axis of that piston and creates a linear force.

Returning the piston to its original position through fluid supplied on the other side or via a spring back force.

The mechanics of an electrical actuator is quite different because it entails converting the energy into torque. A mechanically-connected electric motor turns a lead screw.

What prevents the screw from rotating is either a ball nut with matching threads or a threaded lead.

As the screw rotates, driving the nut along those threads. The direction by which the nut moves is dependent upon the direction where the screw rotates, which likewise allows the actuator to return to its original position.

Both hydraulic and electrical systems have their advantages. Still, you can count on hydraulic actuators to be more suited for high-force applications as these rugged actuators can produce a force that is 25 times more powerful than pneumatic cylinders the same size.

They can operate in pressures as high as 4,000 psi. They can even hold torque and force constant without requiring a pump to supply more fluid or pressure because it uses incompressible fluids. You can put the motors and pumps away at a certain distance without much power loss.

Meanwhile, electrical actuators are the kind of systems you can rely on for precision control positioning at the highest level.

The accuracy range is at +/- 0.000315 in. while repeatability is less than 0.0000394.

They are setting it up to be scalable for any force requirement or purpose.

They are smooth, network-friendly, reprogrammable, repeatable, and quieter compared to Hydraulics and can give you diagnostics or maintenance feedback immediately.

A hydraulic actuator can perform a much broader range of force and speed specifications than an electrically powered one of similar size.

The hydraulic motor maintains torque and force at constant rates without needing a pump to supply added fluid to increase pressure.

So the choice of pneumatics, Hydraulics, or electricity is determined by the application, capital cost, and operating costs.

Research and improvements continue in all areas to improve each one and maintain constantly changing competitiveness among the available systems.

Hydraulics Pneumatics, or Electrical? It is a valid question to explore and always better to ask before starting a project.

 

In modern industrial plants, electronic equipment is used for motor control, and most of not all machines are controlled by PLC’s. The high heat dissipation from electronic equipment exposes control systems to elevated temperatures that make them susceptible to malfunction if too hot, creating unpredictable behavior or failure that could lead to a plant shut-down.

Electrical enclosure temperatures are should be kept well below 106 ºF (41 ºC) to limit the possibility of severe damage to equipment. The heat load from electronic equipment limits the practical use of natural ventilation to cool the electrical enclosures resulting in the adoption of alternate methods.

Fans with Filters

The simplest and often lowest cost solution is to use fans to remove waste heat by circulating ambient air throughout the enclosure. This works provided the ambient air temperature is moderate if the enclosures are well shaded, and when the internal heat generated is low. Filters must be used to keep out dust and debris from the factory atmosphere and need to be cleaned and/or replaced regularly depending on the nature of the plant environment. Normally the cooler air is blown into the bottom of the enclosure, and exits “hot” at the highest point of the control panel. Fans must be sized to provide sufficient airflow to remove the heat generated by the electrical controls.

Again, the use is limited to electrical enclosures with relatively low heat loads, in shaded areas, and where the ambient temperatures are moderate. If the environment is very dusty and even if it contains a lot of oily mist, the replacement of filters can become quite a time-consuming and costly endeavor. This often results in filter neglect, which can create heat removal problems finally resulting in potential damage to the enclosure controls and downtime.

Air-to-Air Heat Exchangers

In difficult factory environments, with moisture, heavy dust is present, and oil or chemical vapor, the cabinet or panel enclosures must be sealed. One method is the use of closed-loop heat pipes.  A heat pipe absorbs the heat inside the enclosure and transfers it to the outside using a thermally conductive, phase-changing liquid under a partial vacuum.  Heat pipes are used extensively in laptops to remove heat from processors for example. Inside the enclosure, the liquid in the heat pipe absorbs heat and converts it to vapor. This vapor moves to the other end of the heat pipe which is outside of the enclosure, transfers the heat to the outside, and changes back to a liquid. The cycle repeats continuously with no moving parts, which makes air to air heat exchangers a relatively low-maintenance solution.  The only components that require electricity are two small fans outside of the enclosure to cool the hot ends of the heat pipes to begin the cooling cycle again.

Although relatively low cost and simple, the cooling application is again limited by the outside ambient temperature in the factory as you cannot cool to a temperature below ambient. Fans involved in cooling the heat pipes still require filters to prevent them from clogging and damage and again, if not replaced, can stop working causing the cooling system to fail.

Air-to-Water Heat Exchangers

If a chilled water supply is available, Air-to-Water Heat Exchangers can offer sub-ambient cooling. The internal components of Air-to-Water Heat Exchangers are normally completely encased within a sealed enclosure, thus providing maintenance-free closed-loop cooling. These systems are ideal for the dirtiest industrial environments where oil mist, dust, and dirt would quickly clog the filters of the earlier mentioned systems. Metal grinding and stamping, automotive brake plants, flour milling, and mining operations are all examples of very nasty environments where the applications for Air-to-Water Heat Exchangers can be applied. Similarly, food processing, especially meat and poultry processing plants where frequent wash-downs are normal, are ideal industries for their use.

A major issue is the quality of the water used. Scale buildup can be detrimental if water treatment is poor or nonexistent rendering such systems unable to remove the heat adequately. With zero discharge regulations in many jurisdictions, water itself is not low-cost anymore and downtime for descaling is a cost that needs to be considered. However, there are some excellent environmentally friendly, and safe descalers on the market such as Alpha Descaler for not only maintenance but also for regular treatment to prevent scale formation.

Air Conditioning the Enclosure

In harsh environments that are also hot and humid and where the enclosure heat loads are high the only workable option is an industrial-grade air conditioner. Traditional air conditioners using chemical refrigerant coolant are designed to work with sealed cabinets and prevent the drawing in of moisture, dirt, or other vapor from the environment. Capacities vary from 1,000 BTU to 20,000 BTU and models are available for standard NEMA 12 enclosures or NEMA 4 and 4X enclosures for harsh and corrosive environments. Options to prevent corrosion in corrosive environments and for outside use in rain and/or snow protection can be used. Due to increasing environmental regulations, new refrigerants have been developed and introduced which have increased the costs of traditional air conditioners along with their development. Costs increase also due to the changing of certain materials such as seals as old seals may be negatively affected by the new refrigerants. Some of these new refrigerants have flammability issues which can be addressed by design changes (again more costly) but have caused concern for their use in some facilities. And, they still have the issue of filter cleaning and/or replacement which – if not done, can cause damage to the air conditioner.

Increasing in use are vortex-tube operated air conditioners. While they require compressed air for use, they use no chemical refrigerant, are simple in design, have no condensate produced, are vibration resistant, keep out the harsh factory environment by slightly pressuring the control panel, and are virtually maintenance-free. There are no external filters as there are no fans to worry about and as long as the compressed air supply is kept clean with proper filtration for the compressed air, these types of air conditioners can work for many years with virtually no maintenance. They are also much more environmentally friendly with no refrigerants and have zero flammability issues. One interesting factor is that in very high-temperature ambient, you can utilize a smaller capacity vortex cooler than you would a traditional air conditioner because a vortex tube operated panel cooler performance is independent of ambient air temperature, unlike a traditional air conditioner. It only depends on the temperature of the compressed air itself. Many vortex coolers like the Nex Flow® Panel Cooler are available for NEMA 12, NEMA 3R (outside use) and NEMA 4-4X enclosures. Nex Flow® has also developed and continues to develop increasingly efficient cooling systems utilizing vortex tube technology and special systems can be made. This type of air conditioner is the most environmentally friendly and user friendly of any air conditioning method.

Enclosure Cooling and Reliability

Reliability is a huge issue in modern times with supply chain issues, lack of adequate labor, and concern over timely responsiveness when issues occur. The greater use of electronics in addition to higher enclosure packing densities has directed the use of enclosure cooling more toward air conditioners. Opting for systems that are better for the environment, and have minimal maintenance is a definite trend. Additional security in large factories is now provided by the installation of remote alarm systems, or by linking the digital controller to a remote web server that can simultaneously monitor several enclosures. This ensures that maintenance personnel is immediately notified of any malfunction to prevent unplanned incidents from becoming plant outages. In smaller operations, monitoring is still primarily by observation. One simple item to assist in monitoring for any heat problem in a control panel is a Temperature Sensing Label supplied with all Nex Flow Panel Coolers. It is placed outside the panel in one top corner and offers a visual indication of potential heat load issues that a passing employee can easily see and then act upon if necessary.

Thyristors and other solid state devices in variable frequency drives generate a large amount of heat up to as much as 6% in some cases, the average for most about 4.5% of rated horsepower. The amount of heat is directly related to the efficiency of the drive.

These solid state units are typically mounted on heat sinks and cooler air is drawn in from the bottom of the control panel and then discharge the hot air at the top of the enclosure.

The removal of this heat under many situations requires the cooling the electrical enclosure and in most circumstances the only viable method is the use of enclosure air conditioners.

Some of these situations are as follows…..

High Panel Temperatures (Over 105 ºF or 40 ºC)

The internal air temperature of an electrical should not exceed 105 ºF (40 ºC) especially as localized temperatures could actually be significantly higher. In fact, the service life of electronic equipment is practically cut in half for every 18 ºF temperature rise above normal ambient temperature.

Near Other External Heat Sources

In applications such as bakeries and steel production, the electrical control panels may be close to very high external sources of heat. A heat source such as a furnace or oven increases the heat load in the drive cabinet enclosure or panel, since the ambient temperature is also elevated. In these locations, only some air conditioner can be effective for cooling an electrical enclosure.

When Exposed to Direct Sunlight

The temperature inside an electrical enclosure situated in direct sunlight will be much higher when exposed directly to solar radiation. Any control panel that sees direct sunlight could absorb up to 100 watts of heat per square foot of surface depending upon the sun’s angle. Reflective paint can deflect much of this solar heat load but, in most cases the temperature inside the enclosure will end up greater than 105 ºF just from the sunlight, without not even considering the additional heat load from variable frequency drives themselves

Higher Level and Mezzanine Floors in Factories

The ambient temperature on a higher level or mezzanine floor in naturally ventilated industrial buildings is usually elevated because hot air is trapped and stratifies under the factory’s roof. The temperature are elevated normally 10 to 20 ºF above the level found on the ground floor. This adds to the heat load in the drive panels to potentially cause premature failure or incorrect operation of the drive. Again, some air conditioner would be required to keep the drive cabinet temperature below 105 ºF.

Corrosive Atmospheres

Electronic equipment is susceptible to corrosion and corrosive atmospheres such as salt spray in marine environments, corrosive chemicals from some production processes, and even particulate containing chemicals that may be in the surrounding air. Drive panels in such environments should have a dust and moisture proof NEMA 4 rating and be provided with a closed circuit enclosure cooling system or some system to keep out the factory environment.

High Humidity Environments

Most electrical drives have a requirement that they are not used in locations where the humidity is high and especially when condensation can occur. In coastal, hot, or humid environments, condensation will easily happen at temperatures close to ambient. A proper enclosure air conditioner will dry the air inside the cabinet, to avoid condensation. If using traditional air conditioners, installing a heater to prevent condensation overnight or during cold periods may be advisable as humidity may stay high and the heating will help prevent the condensation.

 

Cabinet Enclosure Air Conditioner Best for Variable Speed Drives

The high heat dissipation requirements of variable speed drive panels eliminates the use of simple enclosure ventilation systems in any of the above situations.

However it is ideal for relatively low cost vortex tube operated coolers such as the Nex Flow® Frigid-X® Panel Coolers. These devices are produced in stainless steel to handle any potentially corrosive environment and with bypass systems for continuous purging to keep out harsh atmospheres, designed for NEMA Type 12 (IP54), NEMA Type 3R (IP14), or NEMA Type 4-4X (IP66) for almost any type of control panel.

The intrinsic operation of these cooling systems keeps the control panel humidity low to prevent condensation.

While they may have an increased energy use since they operate on compressed air, this is typically offset by the fact that they do not produce any condensate which may be a disposal cost otherwise, use zero chemicals which can harm the environment and which require costly downtime and replacement, and they automatically create a slight positive pressure inside the cabinet to keep our any harmful environmental air – all with no moving parts and essentially maintenance free operation.

Another saving is because of near zero maintenance and absolutely zero use of filters that need replacement, filters that are costly in material, time and disposal after use.

Taken in total, added energy costs in these applications are offset by savings in maintenance time, materials, less downtime, less replacement, and zero disposal costs.

As mentioned in other blogs and articles, one of the key indicators of a well-made and properly designed compressed air operated air knife is relatively even flow across its length.

When you realize that you are dealing with very small air gaps over a long length, the tolerance and care required to manufacturer and assemble such products can be challenging.

One testament to the quality of Nex Flow® air knives, in particular the X-stream® Air Blade® air knives is that they are fully anodized. That process alone, if not done properly can impact the gap tolerance over even short lengths.

Nex Flow® air knives, (and in fact all aluminum material products) are anodized so there is proper protection for the product in an industrial environment. Most other air knife produces simply are incapable of doing this well, and most do not. If not done properly it can effect even flow and even proper flow from the small gaps existing the air knife (and other air amplification products).

In an article “Multilayer Blade-Coating Fabrication of Methylammonium-Free Perovskite Photovoltaic Modules with 66 cm2 Active Area” by Maximilian Ernst, Jan-Philipp Herterich, Christoph Margenfeld, Markus Kohlstädt, and Uli Würfel”, Nex Flow® is referenced in the experimental section where the 6” Model 10006X X-Stream® Air Blade® air knife was used with nitrogen.

Nex Flow® quality and producing even flow is very important. In fact subsequent to the article when another supplier was used by mistake, they returned hose units to correct the error when they could not get the same, necessary even flow from the poor copy.

We are privileged to be part of these and other research projects that help to confirm the value of Nex Flow® and welcome the opportunity to be part of many more.

Air conditioners of various types utilized in the USA or Canada are required to meet certain safety standards with similar requirements in most other parts of the world. This is extremely important for industrial applications where they are used as enforcement but by authorities and within companies themselves is on an increasing trend.

Legal requirements governing the use of electrical equipment may sometimes appear complex, certain compliance requirements are clear and universally apply to electrical enclosure coolers.

The most important are the following:

OSHA and NEC Standards

The Occupational Safety and Health Administration (OSHA) governs safety and health in the American workplace and are used as a guide in many other countries many which have similar regulations. In 1971 the National Electric Code (NEC) was incorporated within the Construction Safety and Health Standards of OSHA and therefore all electrical equipment must also conforms to both the safety requirements of OSHA and the NEC. Vortex tube operated control panel air conditioners operate with compressed air. However, they often use electrically operated solenoid valves and thermostats, either as individual pieces or packaged together and these items themselves must meet these safety standards. If a solenoid valve for example is modified, it may be breaking a code. An example of this is drilling a hole in a solenoid to allow for some compressed air flow into an enclosure to keep it purged of environment air instead of using a separate air line for a bypass.

Local Authorities Having Jurisdiction

The Authority Having Jurisdiction (AHJ) that operates locally in the USA is responsible for enforcing local building codes and ensuring compliance. Many of the codes in force by the local authorities are based on the NEC, also known as the NFPA 70. However, others may add local addendums or use their own specific codes.

In all cases, before an installation can be energized the installation must be signed off by a local inspector mandated by the AHJ.

Increasing Importance of Nationally Recognized Testing Laboratories

To ensure that electrical equipment conforms to the relevant codes is to have the equipment certified by a Nationally Recognized Testing Laboratory (NRTL). This certification will be accepted by the AHJ. There are more than a dozen NRTLs licensed in the USA but the most well-known are UL (Underwriters Laboratory) and CSA (Canadian Standards Association).

Before selecting enclosure cooling equipment, make sure that the equipment has been certified and carries the NRTL certification mark. These testing laboratories do more than just “test”. They ensure that the materials used in the products meet a certain standard of quality. One issue with vortex cooler “knockoffs” for example is not only potentially poor quality, but also the use of below standard materials and parts that require a certain level of testing and approval. Anything below “standard” is risky with anything electrical or electronic.

Specific Canadian Requirements

Enclosure cooling systems sold in Canada must conform to the Canadian Electrical Code Part 1. The Canadian Standards Association (CSA) and certain other testing laboratories such as UL are accredited. There are some variations in test requirements and levels of acceptance between the USA and Canada to distinguish between American and Canadian certifications.  UL for example puts a prefix C next to their mark and refers to both the USA and Canada approval. Sometimes both a C and US prefix and suffix is used to identify that the product is tested to the standards of both jurisdictions. It’s important to understand this difference so as to avoid the possibility of installing equipment with the incorrect certification for your region. CSA is based in Canada and again does the same with prefix or suffix identification to indicate approval for one or both jurisdictions. Nex Flow Panel Coolers have been tested and approved by UL to meet both Canadian and USA standards and bear the appropriate mark.

Hazardous Areas

Equipment designed for use in a hazardous area must also be certified as such. Your enclosure cooler must conform to the specific hazardous area rating applicable and must be compatible with the rating of the enclosure on which it is used. Proper wiring and connections should be particularly checked.

NEMA Type Enclosure Rating for the Enclosure and Area

The enclosure cooling system used must have the same or better  NEMA Type enclosure rating than the electrical enclosure itself. These NEMA Type ratings indicate the design level of the enclosure and the cooling system. For example NEMA Type 4 enclosures are suitable for applications and environments where the panel is subject to wash down. The vortex cooler (or whatever cooking is used) needs to be same or better for that wash down environment. Europe uses IP ratings. Various sources can provide the IP rating that is equivalent to the North American NEMA Type rating. Vortex Coolers like the Nex Flow Panel Cooler have versions tested and approved for NEMA 12 (IP 54), NEMA 3R (IP 14) and NEMA 4-4X (IP 66) applications.

In the U.S. and Canada, it is mandatory for certain equipment to carry the mark of an approved testing laboratory, and an enclosure air conditioner is on the list. Verify before you buy and be safe by using properly certified parts and equipment.

Is the supply chain broken?

Today we see a lot of stories about the supply chain being broken. And there may even be a truth to that. But the issue is not new.

In the last ten years, whenever a work slowdown occurs or a strike since inventories are deliberately kept low with the prevalence of just-in-time manufacturing, other factories in the production process would sometimes have to shut down or slow production due to a lack of parts. As long as there is no glitch in this system caused by a work slowdown, natural or another disaster, it works well.

No system is perfect. Every system comes with a list of important factors and certain assumptions. And of course, the system caters to the most important chosen factors, whatever they may be, and works off those assumptions.

One assumption that is at least implied for the modern production process is the prevalence and relative abundance of supply promptly. Another assumption is that even redundant supply options will occur if a disruption occurs. As some pre-pandemic instances have shown, a labor strike at one facility can and does affect production and jobs at related facilities. But they have tended until now to be somewhat controllable or at least tolerable for a certain length of time. Culturally most of us have become used to on-demand service.

An inventory does tie up funds which means it is an opportunity cost which is one factor driving this philosophy. And again, the expectation that what you need is easily available has been met until recently, so the key assumption has been met.

There has also been a tendency to shut down even profitable facilities and expand to more profitable locations since the acceleration of globalization, especially in the last twenty years. It does not just work moving from one country to another but even within a country. One profitable factory has often been closed as the work is moved to a more profitable location which is then expanded, even within a country. But now, with one location instead of two, should that one operation have a problem, it then has a larger ripple effect in factories that need supply from the affected location.

With limited oil refineries, for example, a bad storm affecting a larger, more centralized production facility can shut down a major supply source of refined oil, as it has numerous times in recent news.

In the last century, globalization accelerated in the 1990s and continued into the twenty-first century’s first decade. This increased supply as well as reduced the price of many goods.

Is the supply chain broken?

The 1980s experienced something else related to this globalization. The system focused on optimal productivity related to the just-in-time concept. It was becoming acceptable at this time to allow certain breakdowns if it optimized profitability. By the mid-1980, redundancy in personnel became an issue. Often operations had more personnel in certain departments, especially maintenance with assistants; employees, who were trained or mentored, and help appeared to be relatively abundant.

When the economy experienced a major slowdown, many personnel, sometimes the most costly (but experienced) lost employment. Also lost was a valuable experience, and mentoring has all but disappeared. This period, I believe, contributed to the modern era of hiring back retirees as the system lacks the passing of necessary knowledge. This is not the only factor, but it contributes to it. It’s not only minimum inventory but minimum labor. That persists today, but we lack labor, as with the lack of inventory.

The root of the problem goes back to the 1970s. In that decade, the just-in-time system was implemented by Toyota as a way to minimize inventory and related costs. By the start of the following decade, it was implemented fully in the rest of the developed world.

I remember a time in 1979 when there was a steel shortage in North America, and customers were put on allocation due to a supply shortage. (Yes – the world has experienced shortages before and more than once.) From 1974 and the next twelve years, the American steel industry was mired in a deep depression, the primary cause being the ten-year economic downturn sparked by the OPEC oil embargo and the Iranian revolution. Eventually, the market adjusted, and steel became a more common commodity, although not necessarily from North America.

The major assumption of always having available material and that even any disruption is temporary and with acceptable (most overall productive cost) is now severely challenged in 2020 and 2021 some modification to this model and philosophy is necessary.

Is the supply chain broken?

So is there a solution? Of course, there is! But, it is certainly not waiting for things to return to some imagined old normal. Why would anyone want to return to a system that was always broken?

The primary focus of the just-in-time philosophy was low inventory to reduce cost and free funds to pursue another opportunity cost. Supply and inventory are already being addressed. Rare earth minerals, for example, are stockpiled now for fear of lacking adequate future supply. Microchip shortages will not end for perhaps a couple of years, but new factories are planned and in the process of being built. Even our company has increased inventory dramatically. That, in turn, affects the customer’s cost and end price. And even opportunities must be slowed or delayed. It cannot be avoided. Costs will be higher – period. Holding more inventory is expensive. Security of supply is now a major, if not the major, issue in manufacturing, with labor not far behind.

Dealing with opportunities is affected by less available funds that are now tied up in inventory. But adopting new technology and anything else that can still allow the pursuit of opportunities more efficiently is accelerated. There is a stream of projects on hold, and ways must be found to allow those projects to advance. Once the money supply is tightened (and it will be at some point), that will further affect opportunities and how fast (or slowly) they can be pursued. Technology is being challenged as well to address labor shortages. Robotics is booming.

In my opinion, the system is still broken, but maybe it always was.

From the current situation, we will emerge into a new, possibly more stable system but in a very different world. Items will be more costly but maybe with much better quality and longer life. Higher prices push customers to demand more, so I expect the quality and life of products to become much more relevant, especially as supply may be restricted for some time. The market responds with demand for higher value, given the higher prices that will be charged. There are many things we used to wait for, even save for long ago, before “on demand” became an accepted part of life. And we paid much more when compared to the current dollar value. This old may become new again.

Of course, we cannot be sure the above will be the result but we certainly can surmise.

And then we will have another system, based on new assumptions, that will, for the most part, be workable, and we will only come across clues to its weaknesses over time and probably ignore them as we have before. Still, it will be fine until some other world event points out where it is broken more dramatically.

Common Errors by First Time Buyers of Specialty Pneumatics

No matter what the technology, the buyer should always be aware that they get what they pay for. As a simple example, recently I purchased a low cost cable replacement for my mobile phone – it was low cost. It lasted only a week. Then I got a more expensive cable, and it still works after three months. It looked the same but was not the same. There were even some more expensive cables but for me, I settled on what I deemed to be a fair price. I based it partially on name recognition but also for my particular needs.

Here is a true story. One of our customers purchased an air knife and was told it would work the same as Nex Flow®, It looked the same and was even about the same cost. However, it did not work properly and was replaced with another Nex Flow® air knife.

It can be the same situation for any industrial item.

Pneumatics is not a technology that is taught extensively.

Much of the knowledge is split up into different sub fields. Air compressor specialists are not always that familiar with filters, filter experts with other parts of the system, and piping experts focus almost exclusively on that aspect. There is little written about specialty pneumatic products such as air nozzles, compressed air conveying and vortex tube technology except by suppliers of these products and most of that knowledge can be traced to really only a few expert companies.

To truly understand that technology you need a long duration of exposure to gain the experience to really use it properly. This means not only knowledge of the product itself, but the installation conditions that effect its use, its performance success and its longevity.

Something as simple as an air nozzle is a perfect example. Several engineered air nozzles may look almost the same on the outside but it’s also the inside that matters. Even performance specifications can be similar but when applied in the field can vary greatly for many reasons.

There are 4 key things to consider when evaluating specialty pneumatics for blow off, cooling or conveying:

• If it looks the same, is it??? Experience.in producing an item as well its design throughout is important. Over the years many replacement part companies have been created and some are quite good but, they usually have a history to indicate competence in producing the part. Often a review of web site content can give a clue. Does the company have a wide range of products and accessories? Have they posted informative articles and examples that are useful? Do they have any special designs and perhaps even patents to indicate a knowledge of what they are offering?
• How quickly does the company respond and do they respond with knowledge? Response time is very important in any request for assistance. Does an email get answered quickly? Does a phone call get returned quickly? Even with remote work in place for many operations, response time is important. The quality of support is not something created in a day – experience, personnel training, application history, all contribute to competent support. How your questions are answered in a call will give clues to the level of competence. We had a recent conversation with a customer in Europe that decided to work with Nex Flow® because we went beyond just offering a sample to test. We discussed the application in greater detail and appled past experience to address it properly.
• Does the product that requires approval either for legal reasons or because of normal and accepted industrial standards have the approvals? For example, all Nex Flow® Panel Coolers have been tested and approved by Underwriters Laboratory to not only meet US, Canadian and international standards, but also to insure that proper material is used in their construction. If something goes wrong on your electrical panel using an untested, non-approved product can be extremely costly on many levels. There is increasing requests for certifications which we welcome. It never hurts to confirm the “value” of the product.
• Delivery is very important and for items like spare parts, it can be extremely important. If it takes unusually long to ship a simple order, you need to question reliability if there is no valid reason.

There can be a wide range of price difference across brands of any particular product. Nex Flow® believes in fair value at a fair price, with good quality and service and support.

Always explore the total cost no matter where the product comes from. Because of our many years of experience in compressed air, and especially with our specialized technology for blow off, conveying and cooling, and because of our approach to innovation as evidenced by our existing patents with more pending, that we can offer our consulting services to address applications more thoroughly and incorporate other technologies with our products.

Nex Flow® has the capability to do special projects others in the industry cannot or will not attempt. It’s never just the product. It’s never just the service. It’s the competence at every level you need to consider from the material, to the manufacturing to the delivery, to the service.

For information on our consulting service use this link: https://www.nexflow.com/products/consultation/compressed-air-application-consulting/

When costly electrical and electronic equipment that maintains the operation of a factory go down, production stops. Critical servers and security systems that drive production is of primary importance in a manufacturing operation not only for production but even for employee safety.

Maintaining the right temperature inside electrical and electronic cabinets require a reliable cooling system. Elevated ambient temperatures in a factory environment can cause costly system failure.

1. Reliable Cooling systems enhance the useful life of controls.  When temperatures rise above maximum operating levels, electrical component life can be reduced significantly. A reliable cooling system keeps the panel temperature below the manufacturer’s recommended maximum value, something simple fans and a building’s HVAC system cannot guarantee.

2. Employee Efficiency is increased. Any company wants employee time spent on improving the business and the bottom line, and not dealing with unexpected breakdowns. While the unexpected does happen those related to control panel shutdown can be reduced dramatically with a reliable cooling system.

3. An Ideal Air Conditioning Systems is Maintenance Free or at Least Minimal.  Most cooling systems require regular checks, such as filters on an air conditioned panel. If not changed regularly especially in a dirty environment one of two things can happen: if not changed a dirty filter can cause poor air circulation and overheating or, if the filter is missing, then dirt can get inside an enclosure and coat, and damage controls or at least reduce their lifetime significantly. Too often these things get missed or just ignored due to lack of maintenance time.

4. Prevention is Always Less Costly.  Preventative maintenance starts with machines working in a properly controlled environment. Just as people work better in a better environment, so does equipment. Poor temperature control inside electrical and electronic enclosures is damaging both economically and from a safety perspective. The use of an efficient cooling system is both economically more profitable and much safer to personnel.

Let’s go deeper on each of these points.

Reliability is becoming more important as labor costs and even labor shortage increase over time. It is important that ANY product for cooling is reputable both in quality as well for technical support should anything actually go wrong. But it’s more than just the supplier’s reputation. Any product chosen should consider the factory environment in which it is placed. Utilizing a fan to cool the inside of a control panel in a dirty and hot and humid environment without considering the environment in which the panel exists can invite trouble. The manufacturer of the control panel does not always have control or any say in which the panel is placed. If the environment is nasty then that should have a serious impact on the cooling method chosen.

Employee basic responsibility is to keep the plant operating. This means an acceptable preventative maintenance program and not only just responding when a problem occurs. If problems persist, the more thorough investigation should be made. Too often however, the problem is not addressed and much time and cost is spent fixing things over and over. For control panels, if the panel door is consistently “left open” because it’s just too hot inside the enclosure, then it should be addressed. It is not only unsafe to leave electrified enclosures open while operating, it is also in most placed illegal. Addressing these problems expeditiously can only improve the environment overall as well as reduce downtime and other potential problems.

Labor costs are significant in any production operation and labor efficiency is important. Every time an outside service person is brought in, some employee must escort that person in the factory, perhaps spend time while that person goes thru a safety protocol training and of course, there is downtime when maintenance is done. Even if no outside person is needed for service, there is still a downtime cost when maintenance is performed by employees. If labor cost can be optimized by reasonably priced solutions that are relatively maintenance free, it should be done.

Prevention is helped by a properly maintained preventative maintenance program and can be further improved by monitoring. There has been and continued=s to be tremendous advances in monitoring of all sorts of equipment especially rotating equipment such as pumps and motors. But what about control panels? While so much is spent for monitoring other equipment the electrical and electronic enclosure should not be ignored. It is just as important in any production line since it keeps that motor or pump running!

HERE IS A NEX FLOW®SOLUTION especially ideal for hot and dirty environments:

We suggest the Nex Flow® Frigid-X® Panel Cooler

They are:

1. Reliable as they do not require electricity to function,
2. Free up Employee Time due to its reliability
3. Essentially Maintenance Free with no filters to change or worry about and even keeps control panels clean by keeping out dirty plant air, and
4. Prevents Downtime due to Overheating by maintaining the proper environment inside a control panel.

Every Panel Cooler comes with a Temperature Indicator sticker that you can put on the outside of a control panel to indicate if the approximate temperature inside the enclosure. Extra stickers can be purchased for other panels. Monitoring does not always need to have a high cost.

 

Seven Ways to make your Compressed Air Blow off and Cooling More Efficient

The majority of compressed air is used for blow off and cooling despite the push for alternate technologies like blowers simply because it is still the most efficient to use in a given application, either because of inadequate pressure from blowers, space problems or high capital and maintenance costs.

This is the reality and which is why compressed air use continues to grow.

So how can you make your compressed air use more efficient for blow off and cooling?

• Look at the compressor room – do you need to address the air supply system efficiency? Can you reduce air compressor unloaded times? A great deal of developments in air compressor technology itself can improve overall supply efficiency which in turn increases end use efficiency. Is it the correct size and type for your factory use? Setting the maximum compressed air pressure to a lower level without harming downstream pressure requirements also reduces costs. Every 10 PSIG pressure reduction saves approximately 5% in energy savings.
• Fix leaks- but not just pipe leaks, leaks at worn connectors which should be replaced, stuck auto drains on filters, even unsealed connections to air nozzles, air tools and other compressed air operated equipment. Because leaks also lowers downstream and end use available pressure, just fixing any leaks can help reduce the maximum pressure settings at the air compressors.
• Check pressure losses – while your factory main compressed air piping maybe adequately sized to minimize pressure loss to the point of use, all too often the connection from the main line to the point of use utilizes piping or hose that is simply too small causing excess pressure loss. This is also compounded with fittings that are too small for the air requirement aggravating pressure loss. It is too common to measure pressure at the main line of 100 PSIG and only three feet away have losses up to 30% simply because the line size from the main to the application was too small. Always check the air requirement (AND pressure requirement of the air nozzle, air knife, vortex tube, panel cooler or any other end use product and be sure that the connection line is of adequate size.
• Proper filtration and dryness – when dealing with compressed air blow off and cooling, devices like engineered air nozzles and vortex tubes require clean and dry compressed air. Any dirt buildup over time and excessive moisture negatively affects performance and can even clog the products. Always use point of use filtration to remove any excess moisture and particulate. Inadequate filtration can not only effect the device, it can also impact the quality of the product where any blow off is used.
• Consider on-off control – a huge advantage of compressed air is that it can be stored and used on demand. When not used, it remains stored and energy is not consumed. Utilizing sensors and solenoid valves or a system such as the Nex Flow® PLCFC can take advantage of this storage ability which can yield tremendous energy savings. Many production lines do not need to have the blow off and cooling constantly on.
• Consider New Pulsing Technology – pulsing of compressed air not new and solenoid valves have been used for years to do this. The problem with solenoid valves is however the high wear and tear and therefore the cost to maintain them typically offsetting any energy savings. It is also not certain how much energy is saved as other factors come into play when pulsing occurs. However, pulsing provides scrubbing action to help clean surfaces and a “push” to move or loosen a target where necessary. New process valves have, and still are being developed for pulsing to overcome these maintenance costs and offer potential for improved cleaning with engineered nozzles and for energy saving when properly applied. has done some projects with pulsing so has experience needed when using new pulse technology and offers consulting services for this as well as other applications.
• Stay informed on new technologies for blow off and cooling but beware of false claims – Nex Flow® and a few other companies do research and development to improve products for blow off, cooling and conveying. Many others just copy, (usually not very well) other’s work and sometimes even claim it as their own. To stay focused, Nex Flow® provides compressed air blow off, cooling and conveying products and stays away from things like spray nozzles. Rather than being a supplier of all things, we specialize and share deep knowledge and experience in what we actually know. This is evidenced by our history of success, continued growth and our unique patents of which there are more to come with ongoing R & D and innovation. Be very careful of product claims that make no sense of product performance, some which even defy the laws of physics. Make sure companies that offer blow off and cooling technology can even afford to get proper approvals where necessary such as for control Panel Cooling to be assured they will stay around to service you (and that the product is even legal!). Reliability, timely response, and quality product and service is always important.

Using Compressed Air Amplifiers for Cooling in Industrial Applications

Air Amplifiers, as explained in this article below from 2018, are the most popular products used for cooling for the reasons explained. One note to an ad is that cooling can be accelerated by adding shims to open up the gap in Fixed Air Ampfliers like the FX series or the Adjustable Air Amplifiers. They work so well because the air’s high velocity cuts through the boundary layer of the hot part, removing the heat quickly. The compressed air also has some cooling effect as it leaves the amplifier and goes to atmospheric pressure, creating a slight temperature drop. These products have even been used to “dehumidify” or remove moisture from surfaces as the blowing air absorbs surface moisture.

In many industrial applications, compressed is, or fans, are used to cool very hot parts. Compressed air will cool much faster than a fan, take up less space, and use more energy. This is important if the manufactured part is costly, and improved throughput will improve profitability.

One way to reduce that energy cost significantly is to use air amplifiers or air movers. Air Amplifiers are generally sized from 3/4″ to 8″ in outlet diameters. The most common size for cooling is from 1-1/4″ to 4″. This is because the larger the air amplifier, the more efficient it is for “amplifying” the flow, although small 3/4″ units are used to cool small parts. They work by drawing in atmospheric air from the back of, into, and then through the air amplifier.

Some companies use air-amplifying air nozzles – some which are made up to as much as 2″ in size. However, they amplify airflow by drawing in from the front around the nozzle exhaust instead of through the unit. So they will not amplify as much; with less mass flow, they will use significantly more energy than an air amplifier and produce more noise.

So when cooling very hot parts is necessary, consider using air amplifiers over air nozzles and fans.

Nex Flow® Air Products are specialists in using compressed air for blow-off, cooling, and moving and can assist in evaluating the optimum solution for cooling applications.

With the tightening of labor availability and the increased mandatory safety measures an often neglected area in compressed air systems is to check for leaks.

Compressed air auditors rightfully focus on improving air compressor efficiency usage and on leaks.

The importance of identifying leaks remains strong to minimize energy waste.   The following was posted in 2017 but is still applicable today although more sophisticated systems are now available to detect and even monetize leakage costs as well as increased use of flow metering devices to not only improve efficient use of compressed air, but can also indicate possible leaks.

The average leakage rate in a compressed air systems can be as high as 30%. Leaks in a compressed air system do not always get the attention they deserve because you are leaking an odorless invisible gas that does not represent a direct hazard. Certainly not like a very visible water leak. The increasing volumetric flow rate caused by air leaks gives rise to higher energy costs for generating compressed air.

Even a small leakage with a diameter of only 5 mm (or the total diameter of the whole of many small leaks adding up to 5 mm) in a 100 PSI compressed air network has high cost, i.e. air losses of 65 SCFM. At 2000 hours a year and a conservative cost figure of 25 cents/1000 cubic feet that amounts to almost $2000.00 a year.

There are various ways of establishing or measuring the quantity leaking out:

1. Establish the leak by emptying the compressed air receiver: This involves measuring, for example, the period during which the pressure drops by 15 PSIG. During measuring, the tank is no longer supplied with compressed air. Assuming that the compressed air flows out isothermally, the quantity leaking out of a compressed air system can be approximately determined by applying the following formula:

Volume of the Leak =

(Receiver capacity) X (Initial receiver pressure-Final receiver pressure)/time measured

2. Determine leaks from the compressor running time or the duty cycle of the compressor. This method can be applied to compressors with intermittent and no-load operation only. All air consuming devices need to be turned off or blocked. Owing to leaks in the system air will leak out and the network pressure has to drop. Over a measured period of time the total running time can be noted. To obtain a good representative result, the compressor period should include several switching internals of the compressor

3. Determining leakage by measuring compressed air consumption: Data loggers can calculate the compressed air consumption of a compressed air station via the load cycles of the compressor. Existing leaks can be deduced from these measurements.

Locating leaks can be done by three methods:

Soaping the compressed air connections
Noise development analysis
Ultrasonic measuring devices
It is also notable that 70% of compressed air leaks occur in the last 30% of the compressed air system.

In addition to compressed air delivery piping joints and bends, specially weak spots to check should be:

Leaking quick release couplings
2. Leaking connecting hoses to the respective compressed air consuming devices

3. The use of old, unchecked condensate drains (floating drains, time controlled solenoid valves)

4. Outdated compressed air consuming devices (e.g. Overblowing compressed air tools)

and

5. “Disintegrated” seals on pneumatic control elements

Coanda Compressed Air Flow Amplifiers Explained

This is an update of an older Blog from 2017 expanding on the use of Air Flow Amplifiers.

Air Flow Amplifiers are used for blow off, cooling, and drying but also used for venting applications.

A compressed air flow amplifier works by entraining air along with compressed air. This is accomplished using an aerodynamic effect called the Coanda effect. In this case the fluid (air) follows specific profile angles – like an airplane wing. Just as the Coanda angles on an airplane wing cause the airplane to lift up, in an airflow amplifier the force is directed outward to cool or dry a surface.

The compressed air is mixed with ambient air drawn into the amplifier piece. Two things happen when this occurs. First the velocity of the compressed air slows down as it is mixed with the ambient air. The second thing is that the “mixed air” now has a higher flow and force. So such devices actually can reduce the amount of compressed required for blow off and cooling applications because of the relative increase in mass flow. The process actually converts energy that would be normally lost is pressure drop and noise into flow and the efficiency depends on the Coanda “angles” and other internal modifications to minimize energy loss.

When you get a result you have a certain “amplification ratio” – the ration of output air to compressed air input. This ration will vary with pressure and ambient and compressed air conditions but an average can be obtained. The larger the air amplifier physically the higher the amplification ratio as well. There is a limit to practical amplification of about 15 or 16 to 1 at the exit of the amplifier. This is because, as you increase the amplification (higher entrained ambient air) the velocity slows down weakening the force and velocity. If the amplification is too high the velocity and force become too low to be of practical use. So a balance has to be made. If anyone claims very high amplification ratios be vary of either performance or inflated data. Other things that effect efficiency is internal design and even shim design. Shims are usually used to maintain the gap where the compressed air comes out. If the shim has varying edges blocking flow such as a saw tooth design, you may get increased pressure drop and lower performance. A flat shim or smooth machined gap is typically more efficient. But for compressed air blow off and cooling air flow amplifiers are a great energy saver over compressed air alone, and also a tremendous noise reducer. Properly designed, noise levels can be reduced by 6 dBA or more using such products over pure compressed air blow off.

As mentioned ate the beginning the article, Air Flow Amplifiers are used for blowing, drying and cooling but also for venting as the ambient air is drawn in through the back of the unit. Two major applications are cooling and venting.

Other versions of air amplification like air knives and nozzles can be used for cooling of course but the high amplification ration of Air Flow Amplifiers make them particularly efficient for cooling. The high velocity in combination with the high air entrainments creates an excellent cooling effect superior to that which can be produced by fans. Fans may use less energy but for high valued products that require cooling, any increased energy usage if often offset by faster production speed and output. Also, the Amplifiers can go instant on and off as needed for cooling keeping compressed air cost low.

Venting is another application which is popular especially when portability is important. Welding applications is one example. Air Amplifiers, as stated, can move a lot of air – hence they are often called “Air Movers” so venting is one ideal application, especially if the venting requirement is intermittent since on-off control can be utilized with compressed air. These units can also be used for boosting vented applications if the existing fan system is weak die to excess pressure drops.

Air Amplifiers, when properly understood and utilized can be an efficient method for cooling and venting as well as for blow off applications.

With the recent expansion of the manufacture of medical products where static issues can negatively affect production, it may be useful to clarify the practical limits in static charge removal on packaging machines in particular,

Production speed desired should be as fast as possible and when dealing with plastic and textile materials, static charge can build up quickly to jam production equipment. In addition, static charges attract dirt to a charged part so static eliminator technology should be properly applied, typically with ionizing bars.

To maintain high output, static control needs to be efficiently applied to maintain high output and cleanliness.

Plastic and other insulators can build up a static charge and attract dirt from their surroundings which can be a problem in further processes such as painting, labeling and even packaging. While the most efficient way would be to remove the static charge early, the process may still continually build up a static charge necessitating cleaning of the parts.

One way to do this is by combining static bars with an air knives. You can also combine a point ionizer with an air amplifier. The amplified airflow from an air amplifier or air knife, being laminar, has the advantage of carrying the “ions” from the static device further and maintaining a blow off force to remove the static charge and clean at a distance. In addition, the units are compact. Often only a very low pressure is required (2 or 3 PSIG) to clean the part so compressed air cost is minimal.

However, one misconception that is often propagated by those who may not truly understand static eliminators, is that you can remove a static charge at very large distances instantly. The fact is, you can even remove static charges at a distance even if there is no air to “push” the ions to the part. But it takes “time”. What the air does is both remove the dirt and dust from the surface of the item to be cleaned after the charge is neutralized and of course, neutralizes the surface with the “ions” it carries to the part. But, this takes time – the time increasing to several seconds or longer the further you are away. The reason is that the “ions” generated from the static device start to re-combine the further you are away from the static device. Hence, it takes longer for the static charge on the part, which is receiving a weaker concentration of ions, to discharge. And unless the surface is discharged, the dirt and dust will be difficult to remove. So when you see claims of removing static charge ten or twenty feet away from the target, be very wary of real effectiveness. If the charge is minimal and the target slow moving, it might be possible to work. But if the charge is high and, or the target is fast moving it may not work.

One way to compensate is to use a much stronger static eliminator and a few companies do have stronger static bars that are shockless and safe to use for this purpose. But standard strength static bars may not be adequate for many applications.

So in considering the use of air knives and amplifiers with static eliminators, consider the nature of the part, its speed (time exposure to the static eliminator and air flow), strength of the static charge to be removed, and distance from the target. You may require a much more powerful static eliminator.

There are other things to consider as well such as how the air knives or amplifier is mounted, materials used, etc. and if you have questions in this regard please ask or visit our web site at www.nexflow.com

Why Does No One Pay Attention to Engineered Air Nozzles – Mostly!:

We are biased on this but it does seem that engineered compressed air nozzles are not top of mind in many compressed air blow off applications.

This is evidenced by the preponderance of open pipe and crimped tubing still in use.

But when you consider that around 70% of compressed air (after accounting for leaks) is still used for blowing or cooling, that’s really a major energy cost that may be ignored.

We believe there are possibly four primary reasons:

• Perception that the Improvement is not worth the cost:

Published claims of 40% or more are quite valid when adding an engineered nozzle to a pipe or tube set at 80 to 100 PSIG.

That statement itself can create suspicion to such a claim.

The actual pressure coming out of the nozzle will be much less from an engineered nozzle. So why not just reduce the line pressure which ALSO reduces air consumption and noise?

When comparing an engineered nozzle putting out 30 PSIG (with 80 PSIG line pressure) to an open tube with a regulator set to 30 PSIG the savings improvement actually reduces to about 10% – but it’s still 10%.

In addition, open tube will dramatically weaken when even a couple inches away due to turbulence while an engineered nozzle can work up to 12 inches away and be much more effective due to laminar flow.

That in itself can affect production supporting the argument for engineered air nozzles based on performance alone even when compared to low pressure output from open pipe or tube.

If you are a machine or system manufacturer, engineered nozzles, especially very small ones can be quite costly adding to machine cost and may find it difficult to sell the value added such products can provide.

On the other hand, it offers a potential profitable value added that can also enhance your company reputation for innovation and superior design and performance.

• Engineered Air Nozzles Plug up and Stop Working:

This comes up more often in very large factories where the compressed air system is old, and frankly, not well designed or maintained.

This can be true with improper filtration but investing in proper filtration, with innovative improvements that have occurred over the years, can offset this concern over plugging.

Energy savings and reduced noise can typically have a one year payback on improved filtration as well as longer term benefits by fixing up an old or previously not maintained well compressed air delivery system.

• Engineered nozzles are not strong enough.

There are applications where high pressure is just plain required for the job and engineered air nozzles just do not have that high a pressure.

The problem is when that generalization of weakness is extended across all potential applications.

That generalization can also be aggravated due to overzealous sales personnel that over sell the technology due to lack of adequate knowledge or bad management.

So if a very high pressure is required such as when you need such force to break off a piece of scrap metal from a manufactured part, then engineered nozzles will not work.

• All Engineered Air Nozzles are the same:

Many suppliers of compressed air operated parts from valves to cylinders not have air nozzles and why not? It’s an easy add on.

The problem is that given any set of nozzles, even if they look almost the same externally, can dramatically vary in performance, air consumption, and energy output.

It’s not just the outside, it’s the inside as well. As such, performance data should be available and if not, demanded, to be assured you actually do have a good engineered nozzle.

For this reason, Nex Flow manufacturers what they know and understand and not things like cylinders which we can certainly make, but choose instead to focus on what we do best and do well.

We love to hear about industry bias. If you have any, please email us at technical@nexflow.com

Pneumatics maintenance

These costs have been rising for years in an environment of decreasing availability of qualified personnel who are in increasing demand and with increasingly complex in house procedures for personnel safety. Maintaining and improving productivity is paramount in any manufacturing operation which is achieved by optimum use of equipment, with minimal energy use and with the least downtime all with the utmost safety. Maintenance cost has become a larger share of overall expense to be considered in any choice of equipment, and just as important as energy cost and the equipment cost along with the equipment operating cost. Over time, maintenance procedures can become more complex for equipment with upgrades and
addition so it is important to know which is the most important for both monitoring and scheduling.

Equipment should not be used beyond the purpose for which they are intended as it reduces their lifespan and negatively affects their ability to work efficiently, resulting in frequent breakdowns and costly repairs.

Preventative maintenance minimizes unscheduled breakdowns but a regular maintenance schedule that covers all essential equipment and accessories reduces overall costs. Technology is becoming more and more cost effective for monitoring key aspects of machine functions for determining a time line for when something needs to be addressed and aid planning. Maintaining and improving productivity is the only way to maintain and improve the bottom line. To do this, companies sometimes focus on only one aspect such as reducing energy costs in a particular application, and will look at alternate equipment costs but sometimes overlook the implications on maintenance expense and the cost of maintenance itself. Yet, these maintenance costs are of every increasing impact. While in some instances the impact of downtime cost and maintenance expense may not be large such as in non-critical areas of the manufacturing process,
but in others it can be quite major. These cases should have a high value put toward the use of equipment that may require less maintenance.

Advantages of a good maintenance program are as follows:
1, Equipment downtime is decreased and the number of major repairs are reduced
2. Increased life expectancy of equipment, and elimination of premature replacement of machinery
3. Reduced overtime cost with more economical use of maintenance personnel and improved technician productivity
4. Scheduled repairs mean fewer large-scale repairs
5. Improved safety and quality conditions for everyone

Compressed air operated equipment and any pneumatic system requires low maintenance and have long operating life. As energy costs go down or at least rise more slowly than the cost of maintenance, the overall cost advantage of pneumatics goes up against alternatives. This is testament to the continued strength and growth in the use of pneumatic tools over electrical for many more reasons apart from just less maintenance and ruggedness.

This is also true in many applications for cleaning and drying and even cooling. For years there has been and still is, a competition between the uses of electrically driven blowers and blower operated nozzles and air knives verses compressed air nozzles and air knives. Blower companies
consistently work to improve blowers to reduce the time between necessary maintenance but cannot battle the rising cost every time maintenance is required. Both electrical blower blow off products and compressed operated blow off products have their place.

 

 

Compressed air operated nozzles and air knives have virtually zero maintenance. The only concern is to be sure that the supply air is clean and dry. To this end Nex Flow has introduced an essentially zero maintenance point of use Super Separator to assure quality air supply. In addition progress has continually been made to reduce the cost of the energy used with on-off control such as the Nex Flow PLCFC system. Even a simple regulator to reduce the pressure to a nozzle or air knife to the point where it still does the job but at a minimum pressure level optimizes energy use.

 

All these pneumatic blow off products last years. Pneumatic products have almost unlimited life as long as the air supply is kept clean and dry. They all have the added advantage of low noise levels such as the Nex Flow Air Blade air knives (69 dBA at 80 PSIG operation). High noise level is an increasingly serious safety concern and could only become more important as the demand by maintenance and also production employees for higher safety standards in a factory environment increase.

Even the effect of climate change can affect the maintenance of some equipment. Air conditioning of control panels is an area where there is a gradual change to non-ozone depleting, and carbon neutral coolant. As these new products are much more costly, more reactive, and that means more maintenance which means more cost. Every maintenance that causes downtime negatively impacts productivity. The risk of having the parts available and the personnel there
when necessary is something always to be considered. Downtime on a control panel immediately impacts production.

Nex Flow Panel Coolers have been popular for use in relatively dirty, hot and humid environments as a maintenance free air conditioner and demand is not decreasing. The company is continually working on improving the energy efficiency of these products and of Vortex Tube technology itself as it still is the only simple and economical alternative, even now when maintenance costs are included. They use no filters for example which not only go up in cost,
the disposal of these filters go up in cost along with the maintenance personnel who have to change them! As with compressed air operated blow off nozzles and air knives, these vortex tube technology products have an indefinite life due to their ruggedness and as long as the air supply is clean and dry, can last the lifetime of the machine on which it is used.

The more critical the control panel that needs cooling, the more important is reliability and a pneumatically operated Panel Cooler is the most reliable as well as one of the most climate friendly technologies which uses no chemicals that can impact the planet – it uses only compressed air – the air we breathe every day

If you can minimize maintenance, you have increased safety and even greater security in your production. The worst nightmare of anyone with downtime is waiting for a part, and certainly keeping that part in stock itself is a cost. Eliminating that worry can be a huge saving in cost. In any analysis always consider the cost of maintenance and how it is increasing over time.

Since getting involved with air nozzles, air knives and other compressed air operated blow off products, one term that keeps getting used and abused is the term air amplification. There is sometimes a false impression created that the larger the number, the more effective is the output and efficiency of an air nozzle air knife or air amplifier. That is not necessarily the case.

Engineered air nozzles, air knives, air jets and air amplifiers typically use special aerodynamic shapes to produce much greater flow, high velocity and a blow off force at a greater distance from the device for any given air consumption. But this does not mean that the higher the air amplification after a certain value, that the force, velocity or flow continues increase proportionally at an indefinite rate and in fact, can decrease if this value is too high. There is a practical limit from simple physics. The term air amplification has been around for years but it is more accurately described as energy conversion – converting energy normally lost as pressure drop and noise, into flow.

When compressed air exits any opening, even an inefficient crimped copper tube, the air flow will entrain some atmospheric air. It varies with distance, with temperature, density, pressure and all sorts of factors but the average figure used is as follows; at a distance of 6 inches after exiting, the moving airflow will entrain about three times the air volume that exits the opening. That is an air amplification ration of three times. As this happens, because you are entraining still atmospheric air, you will start to slow down the velocity of the moving air. The way to make any blow off product more powerful, fast and efficient is to increase the output right at the exit before this “downstream” entrainment. For a crimped tube or open pipe, that ratio at the air exit is one to one. Engineered nozzles and amplifiers attempt to improve on that ratio.

 

The aerodynamic design of engineered nozzles, air knives etc. do this by “recovering” energy that is normally lost as pressure drop and noise level right at the exit of the blow off product. In doing this effect, the pressure of the exiting compressed air must drop. However, the flow tends to remain laminar at this exit point and maintain its laminar flow over a much longer distance. This is what maintains a concentrated force after a long distance as well as high velocity because turbulence is avoided. The actual force “at a distance” coupled with the added mass flow due to entrainment, albeit at a lower pressure, remains quite powerful and effective. As an example, a 2” air amplifier like the Nex Flow Model FX40 has an amplification ratio of 15:1 at the exit point. That is quite a high ratio. The effective air amplification 6” downstream will now be 3 X 15 or 45 times. The mass flow, and velocity at the exit will slow as it entrains that downstream value. But what happens if the amplification ratio is much higher at the exit and, is it reasonable. When there is air amplification the downstream velocity, and force does not go up linearly with amplified flow. In fact, as downstream entrainment occurs, the velocity and force will decrease if the amplification ratio is too high.

In applications where high air pressure is required, then air amplifying nozzles will not always work but, the target of the flow must be close to the air exit of the tube or pipe used in that case. This is because air flow will be turbulent and the force and velocity will dissipate very quickly with distance. Reasonable air amplification “at the point of exit” from an air amplifier, or nozzle can be in the range of 6 to 16 times at the exit. Any more that that is first of dubious based on shear physics and should be questioned. At 6 inches away another 3 times amplification occurs to that recovered figure at the exit. For an X-Stream air blade air knife for example, the amplification ratio is usually about 40 times at 6 inches from the air exit gap. That figure comes from using 3 times downstream entrainment coupled with the recovered energy amplification or about 13 at the air gap exit. For standard air knives, it’s about 30 times at the 6” distance or 10 times at the exit. For air nozzles, air jets and annular air flow amplifiers, it is dependent on the physical size and geometry becoming more effective for flow amplification as the size goes up and can go from 6 times to 16 times at the “exit” of the product. If you see higher figures, you should question them – not because it may or may not be correct, it’s whether what you really need that high a mass flow, and whether velocity and force is going to be what you expect and require.

By understanding the above, a few facts become clear. First, the very term air amplification implies you need to know where that the value applies – at what particular point – either at the exit of the compressed air from the device, or at some distance from the device. Second, air amplification by its nature implies that the higher the value, the greater the flow but… the force and velocity will be less after some optimum amplification point. So at some level, the air amplification can be too high and may actually produce less effective force and velocity at the target.

Some interesting claims have been made for “air amplification”. We describe two as follows:

1. One is a claim that a particular shim design can direct compressed air at the exit in such a way to increase air amplification by over 60% at the exit point. In other words, you get a lot more flow from a given air consumption. The result interestingly enough, has improved business for Nex Flow because these amplifiers did not work as well as previous designs with less air amplification because of inadequate force and velocity. Logically, a greater air amplification ratio beyond an optimum point, may result in more air flow but lower velocity and less force at the target. Both are undesirable results if the use is for blow off or cooling. If the devices are used for venting it would be advantageous although no data is available on any increased or negative change in the effect of back pressure. That can also be a negative factor. There is a balance to what is a reasonable air amplification ratio for an effective result.
2. Another claim is which we have seen is with compressed air operated air knives. One design with two exit gaps for compressed air claims air amplification of 50 times against claims of most others of 40 and 30 times. Same reasoning applies in that flow may be more but force and velocity may be negatively affected. No distance from the exit is mentioned to determine this amplification as point of reference. If it’s a single gap in an air knife that someone claims is 50 times, it should be highly suspect.

Rather than focus on the term “air amplification”, we recommend that you focus more closely at the results you need and look at measured data on force and velocity and the actual air consumption. What is the force at a given distance? What is the velocity? Check the compressed air consumption against the force and velocity produced. What you really need is a high force and velocity ratio to air consumption. That will give a true reading of efficiency that is both useful and understandable. Of course – make sure those published values are valid as well. When using air flow amplifiers for venting, any attachment at the exit – a hose or pipe, will create some back pressure that will dramatically reduce the back pressure. Sensitivity to back pressure is important and the higher the amplification ratio, typically the more sensitive to back pressure the device will be as well.

 

In summary, recognize that air amplification and the term “amplification ratio” is a guide to efficiency but more of a qualitative indicator that is often not clearly defined as to how it is obtained. If the value appears out of the ordinary, it should be suspect.

To get a true measure of efficiency, check the measurable results – air consumption, velocity, force, and especially force/ air consumption ratio which is a realistic and objective indication of efficiency that is both verifiable and useful in determining its effective use in any given application.

Understanding quality and safety

It’s not only consumer items which have knockoffs but many industrial items as well. One very familiar one is replacement compressor parts. Some might be OK but….. when it’s a copy, you take a risk.

Some companies even make Nex Flow® knock-offs which when checked, are of dubious quality and one even potentially infringed a patent which the company had to address legally. The copy was also done so badly it did not work!!! A reason to address any knockoff of a product is of course to prevent your own good product from being mistakenly identified with a bad copy. We discovered all this when a customer came to us after their supplier stopped calling them back once the product, which was a Cabinet Enclosure Cooler, was found not to work. It was actually quite shocking when the copied product had a piece break off. The manufacturing was simply not good. Imagine this knocked off product on a control panel!

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One area of the world where copies and even copies of copies are prevalent is in parts of Asia. Every major manufacturer of our technology has been copied and re-copied with various degrees of quality. The further down you go in this chain of events, the worse it seems to get!

Here is an example of a product, made in China that copied a well-known air nozzle manufacturer (not us by the way).

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It looks the same but…. what if the material is inferior? What if the product breaks and negatively affects production or worse – what if it breaks and someone gets hurt? Poor quality material will wear out faster. Most would want to avoid such knockoffs despite sometimes lower price simply for safety reasons. Here are things to look for when choosing any product which may have perhaps even several copies on the market.

 

Understanding quality and safety. Look at the web site of the company:

1. Does the web site have a wide range of products or just some that other competitors have? One relatively easy thing to do is simply compare the extent of the variety of product content. Does it appear that only the “easy” items were copied?
2. Check the address. Even multiple addresses may only be mail drops for couriers. Trying to provide an image of a large company with multiple locations that are just mail drops is suspicious. If the company is not truthful about their real size, then what else is not true?
3. Look for the quality of the web site content. Has it simply mimicked what another company has done and maybe just altered some data? We found one copy using the same performance charts for the same copied product but changed the data slightly – not the real information which we tested. It has happened, when a company has called us thinking it was our product wondering why it did not match the false data. An honest company uses honest data but when someone copies, it is very tempting to embellish data to stand out (and also avoid obvious copyright infringement).
4. Does published data make sense? One term that is overused in our industry is the term “air amplification ratio”. There is no real standard approved definition. For example, an old-style air knife design (like our Nex Flow® Standard Air Blade air knives where exiting air flow bends 90 degrees) gives an amplification ratio of 30:1 at 6 inches away. The X-Stream® Air Blade air knife where the air comes out straight gives an amplification ratio of 40:1. Similar looking products will logically have the same figure. But, if suddenly that figure jumps to 50:1 without any explanation, something should be suspect. The best way to compare performance from air knives is really to compare force and velocity figures at the same distance at the same pressure to the air consumption. One thing to seriously note, is if the amplification ratio is too high, it in fact indicates weaker performance as it would slow velocity more and reduce blow off force. But looking at explicit, measured data is the best way to check the quality of performance.

 

Understanding quality and safety. Look at Approvals, Certifications

1. Certifications such as those performed by UL or CSA or any other international body are the best way to insure a certain level of quality. For example, Nex Flow® Frigid-X Panel Coolers have been RUL tested with Type 12, 3R, and Nema 4/4X certification. That means several things, that materials used in the construction of the product are of a certain level of quality – no cheap substitutes that can wear our earlier in an industrial environment. And for sure, safety has been a big consideration in testing. If there is no certification to some standard the product should be suspect. The example of the disastrous knockoff described at the beginning of this article is a perfect example – it has no certification.
2. Are there strict manufacturing standards and testing in place. When Nex Flow® products are made, there are strict tests and checks that must be done before the product is sent to the market. Even many customers require us to assure that certain standards are met. Great care is made in the choice of materials and in sourced parts. If a product is suspect, ask the supplier what their standards are, how they insure quality.

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Understanding quality and safety. Does the Company Innovate, Service well, Product available, personnel available?

1. Some knocked off products are marketed by part-time companies. One clue is a lack of innovation compared to other companies that offer much more, have more data to provide, and have some indication that it is a real serious business such as product development. If the company has some patents, that is one indication that is a serious company that will be around for a long time since patents are not inexpensive and take time, effort, and cost to create.
2. If the response you get when you call is an answering system with a rather poor quality message that should be suspect. What is more important is if you do not get a response for a long time to your message, or no response at all. It is not impossible that the owner could be out at his “real job”. If something went wrong, would you not want a quick response? Answering systems are certainly fine to have but it’s the response time you need to assess. Availability is important.
3. One important feature of our industry is product availability. Most products are stock. If the product you are seeking is not in stock, or it takes several days to package and deliver, that is a clear indication of a part-time business. Nex Flow®, and other serious manufacturers in the industry realize that having stock is important, and same or next day shipping is the norm. You should expect that except for those unusual situations which can occur in any business, where you have a rush on a particular item. But if you order something, especially if ordered online, and it takes several days to ship, it is suspect.
4. Does anyone you contact for technical support help you? Do they sound like they know the product? That is certainly important. If they do not know the product well, that can be a waste of your time. You need confidence that what you purchase will work for you.

 

Innovations by Nex Flow®:

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Check Internet Presence and Reputation

1. Does the company have a decent web presence? This is not just spending energy for showing up, but also their contribution to education, and positive contribution on social media. Do they publish articles and blogs on a regular basis that actually go beyond simple product descriptions and sales? It’s not only quantity but the quality of postings.
2. What online reputation do they have? Has anyone complained online? Any better Business Bureau complaints? Has anyone recommended them? Beware of Case Studies that cannot be verified with real references or at least real photos that are not photoshopped.

When purchasing a product you want a fair price, a reasonable level of quality, assured support, and to be secure that it is safe. Keep in mind the above when contacting a potential supplier can help you assess if the source is reliable and that the product you purchase is what you expect, and that you have the security of proper support if needed.

Understanding quality and safety

The corona virus has disrupted virtually everyone’s lives around the globe.  While some people may hope it will return to normal, realistically there will certainly be some things that will not be the same.  We have yet to really know what the new normal will be.  But one thing for certain, is that everyone’s priorities will shift and are shifting even during this crisis.  Moving forward this will affect not only where we work, but how we work and how we will even make decisions at work.

There will be changes in cost of materials, costs of energy and labor cost and it’s anyone’s guess what will go up and what go down at this point.  But one thing that will change is what we consider is most important to least important.   In addressing this, we are thinking primarily of compressed air technology – from air compressors to end use products – although the thinking may certainly apply to all factory purchases.

When making any purchase for a manufacturing operation several factors are involved but typically a few take priority over others.   The factors are inter-related and at times can be complex.  Capital cost is important especially if there are budget limitations and often quality and capital cost are closely related.   Capital cost and operating costs have tended to be the overriding priorities with a certain payback required.  But this may not be the most important moving forward or at least not the only key drivers behind a purchase.  Improved safety may a motivation to purchase a product especially if post corona virus factory environments mean more workers working individually instead of in pairs or groups.  Will factory workers working more individually demand a better working environment such as lower noise levels, enhanced safety?   Will they demand better training and support?  And from where?

Ease of use of the product rise in importance as well as support and training.  Where the product comes from may become more important for security of support and spare parts.   Cost and safety of the product may be closely related.   As lower cost supply chains get disrupted there can be greater focus on innovation that can improve productivity.  When dealing with compressed air, energy cost has received a high priority but with energy costs changing, will it remain the most important?   Which will be more important – productivity or energy cost and how will these factors change in relation to each other?

In this time of massive change, what do you consider to be the most important when deciding on purchases relating to your compressed air products and/or systems from the air compressor to the end-use product.

 

Rank the items below in our survey.

Restarting your Compressed Air System

With many shutdowns in place of manufacturing deemed non-essential due to the corona virus, there will need to be restarts to factory compressed air systems when the factories are started back up. Many of these operations will have sat idle for a significant period of time. For the idle air compressor, it is akin to storing a car for a long period of time. And in addition, the entire system attached to the air compressor system must also be considered.

It is important to check that it is in good shape before starting up the system. Things to check:

1. Do a walk around and check for possible oil leaks and check hoses and fittings. When hoses and fittings cool down they can become brittle and hoses can easily crack on startup. If there is any oil where oil should not be, check for any degradation in parts of the piping, hoses and fittings and repair/replace as necessary.

2. While doing the walk around, check all filters in the system and check for any stuck auto drains, and ensure all filters are drained of collected moisture and dirt. Open all manual drains to
remove any condensed moisture that occurred during the shutdown. This is also a good time to inspect and do maintenance on any filters which may need them such as replacing saturated
cartridges.

3. While the system is down, condensed moisture in the piping may leak out through leaks. This is a good way to identify any leaks in the system for repair prior to startup. Very large plants may have manual or auto drains at many low points to collect condensed moisture and dirt. These are especially important to check and drain as a significant amount of condensate may have been collected during the shutdown.

4. For end use, check the startup procedures for pneumatically operated equipment and whether they need to be isolated prior to providing it compressed air, and solenoid valves in particular
need to be checked as they may stick after sitting inactive for a long time. The solenoid supplier can advise on what do in the case of a startup after sitting inactive for a long time.

5. Back at the compressor, check the oil if the shutdown has been for a long time. Just like a car in storage, the oil can degrade and may need changing. Belt driven compressors should have the drive belts checked as well for proper tension.

6. In warm climates, for large horsepower air compressors, it may be wise to perform an insulation test on the motor to make sure moisture has not collected on the inside.

7. Check air tools, and any blow off nozzles, air knives and any vortex coolers to make sure they are clean prior to startup. Remove, clean and replace as needed. The point of use filters for
these items especially should be checked to make sure any moisture and dirt collected is removed to avoid carryover to the tool or nozzle and then possibly onto the manufactured product.
Much like anything left idle for a long time, one needs to consider the factory environment and local climate conditions that can have any deleterious effect on the system that may need to be dealt with – much like a car left in storage for an extended period.

Compressed Air for Medical Use

Medical grade compressed air is used in just about every area of a hospital and is administered to patients who need inhaled medications and anesthesia, while patients are under anesthesia, for treatment of respiratory conditions, and to power ventilators.

The main uses of medical compressed air are:

• driving ventilators and incubators, where it provides uncontaminated and controlled air
  flows helping to reduce high concentration of oxygen exposure.
• as a carrier gas for anaesthetic agents.
• as a power source for powering surgical tools in the operating room.

Medical Air refers to a clean supply of compressed air used in hospitals and healthcare facilities to distribute medical gas. It needs to be free of contamination and particles, have no oil or odors, and must be dry to prevent water buildup in your facility’s pipeline. When a patient is in any emergency or non-emergency operating room, a surgeon relies on a medical air compressor to keep the patient comfortable and breathing. Medical air sources are connected to the medical air distribution system only and used only for air in the application of human respiration and calibration of medical devices for respiratory application. Besides the use of medical compressed air for medical gas and breathing, medical Instrument Air is compressed air purified to an appropriate safety level to meet the requirements of the Instrument Society of America and the NFPA (National Fire Protection Organization) as an alternative to Nitrogen. Equivalent to Nitrogen in pressure, dryness, and cleanliness, instrument compressed air can support multiple medical applications including driving surgical tools, operating pneumatic brakes and tables, central sterile supply, and laboratory air. Smaller operations that do not want to have a separate compressor and piping line, instead use pure nitrogen out of cylinders for this purpose.

Oil-free and oil-less air compressors are preferred method in supplying medical air, because it is the simplest, safest and most cost effective solution. In the past, oil-based medical air compressors have been known to suffer system failure due to the corrosion of lubricant and the dispersal of oil into compressed air. As a result most hospitals have switched to oil-free air compressors, which are not prone to breakdowns stemming from oil-related issues.

Water and moisture is the most dangerous contaminant to address in medical compressed air systems. It is corrosive, common and costly. Aside from causing damage to distribution piping and air receivers, unwanted moisture can lead to corrosion and mold growth on patient care equipment. Most distressingly, water can pass through filters that are made to block out particulate residue from iron, steel and rust. As such, water in all its forms — airborne moisture, system condensation — leads to endless repair bills and constant setbacks for medical air systems. This is especially important to avoid contamination from virus’ that can be carried by water and moisture. The most common enemy found in malfunctioning vaporizers is moisture, which can travel from machine tanks to tool tips via compressed air. Often, the damage will render such devices beyond repair. With anesthesia machines, a total refurbishment is generally required to make them operable again following moisture damage. When temperatures are low, condensation may form in system piping that can lead to freezing. As water degrades within an air compressor, bacteria can form. Water bacteria can ultimately send pathogens into the hospital environment.

Key areas that should be maintained to avoid water and moisture in medical compressed air

1. Air Dryers. Any compressed air dryer must be properly fitted and sized. Any incompatible design or size, or overused system that causes any insufficient water removal will create costly problems in the system.
2. Aftercooler drains should be checked regularly. If they are weak, worn out, stuck or damaged in anyway, moisture and water can enter downstream into the system.
3. Faulty seals, liquid ring components that are worn can easily cause contaminants and especially moisture to enter a medical system.

Before problems arise, tests to insure cleanliness and dryness are normally repeated at regular intervals and evaluated for patterns in system behavior. Compressed air systems in hospitals must remain safe and sanitary. In times of dire emergencies, the medical compressed air system remains and important part of treatment and must be properly maintained. There are expert companies that can assist with the air filtration requirements for hospitals. For the delivery system air amplification technology and even vortex tube technology is being considered in some applications for air delivery, and even for the cooling of some medicines which may perform better when cooled. For these special applications special materials must be used to meet the high level of medical standards.

Compressed air for the medical industry is a power source that not everyone thinks about or realizes how important it can be. But properly managed medical compressed air saves lives every day.

There are all sorts of electrical certification available today – ISO certifications for quality standards, environmental standards, various country or regional certifications again, usually related to materials used and quality.

Meeting any standard adds cost to a product. Of all the standards that are very critical to most product buyers and users, it is those related to electrical use. No one wants to worry about an electrical plug melting when it is “plugged in”. In fact, such an incident would invite immediate government investigation (and in fact, has indeed done so!). Sometimes, the electrical certification is overlooked with vortex tube operated enclosure coolers because they do not use electricity. But, as they are used on electrical panels, ignoring the approvals can be a significant risk.

Nex Flow® Air Products Corp. has a ULC electrical certification (RUL actually) for their vortex tube operated Panel Coolers to assure they meet USA electrical but also Canadian CSA standards which can be more stringent. This involved extensive testing by the Underwriters Laboratory organization to be assured that any water does not get into a control panel, that it is used properly (properly mounted) and in addition, meets quality requirements in materials used. For example, for NEMA 4X (IP 66) that the materials are appropriate for a corrosive environment and that a direct wash down does not cause water to get into an electrical enclosure. The UL organization does regular checks to assure the product maintains the standard as per the test results performed.

Nex Flow® recently did a cursory investigation into some competitive products, in particular those that have not received UL or any particular certification while they claim that they meet particular and various NEMA standards. While not appropriate to mention names, we were shocked to find that despite their claims, some of these companies failed to meet the standard to keep water out of a control panel. Some units from others worked well to prevent moisture from getting in, but no assessment was made on materials used. When UL tests these devices, the materials used must also meet certain standards and they are evaluated as well.

If moisture gets into a control panel, it can be a costly expense as significant damage can occur. So just like when you purchase an electrical motor, a razor, an electric toothbrush, an electric screwdriver, etc. you want certain electrical approvals to be confident the items do not smoke, burn or otherwise cause potentially major damage. The importance of electrical certification on even a non-electric, vortex tube operated electrical enclosure cooler can be a major factor to reduce the risk of potentially major damage to an electrical enclosure.

Electrical certification on vortex tube operated control panel enclosures IS important.

 

• Our ability to hear is critical for much of our communication yet we don’t realize it until we lose or damage our ability to “hear”.
• High levels of noise can lead to permanent hearing damage and high vibration caused by noise can lead to a variety of significant medical conditions
• At lower levels, both noise and vibration can cause interference with our ability to hear and feel, such as reducing the ease of normal conversation and can be annoying, irritating and unpleasant
• For both noise and vibration there is generally a level below which no adverse reaction occurs
• There are also favorable responses to noise and vibration
• Individual responses to noise can vary significantly but there are consistent trends between noise level, measured in dB(A), and annoyance for the general public.

Nex Flow® manufactures compressed air operated nozzles, air knives and other blow off products with the above in mind.  The technology works by converting energy normally lost as pressure drop into useful blowing and cooling energy with noise reduction a by-product.  This by-product is very important as these noise level reductions can be 10 dBA or more.

 

Many production facilities put a heavy emphasis on the energy reduction from the technology but often fail to consider the importance of noise reduction.

As an example of just how much noise effect your well-being check out this article from THE ATLANTIC: https://www.theatlantic.com/magazine/archive/2019/11/the-end-of-silence/598366/

Options of Dry Machining

The positive features of metalworking fluids have long been established and include friction reduction, cooling, corrosion protection, welding protection from the tool to the workpiece and the washing away of metal chips. However reducing cutting fluid use offers the chance for considerable cost savings. Tool life may even improve. The problems to address in machining involve the following: chip removal, safety, cooling and lubrication where necessary.

Today, the economic cost of using fluid has gone way up —including their management and disposal—account for 16 percent of the cost of the average job, up from under 3% two decades ago. Because cutting tools account for only about 4 percent of the total cost of a machining project, accepting a slightly shorter tool life for the chance to eliminate the cost and headaches of maintaining cutting fluids could be the less expensive choice. And tool life may not even go
down thanks to coatings which have been developed for tooling over the years. In addition, there are safety concerns to deal with in the use of cutting fluids. OSHA established the Metalworking Fluid Standards Advisory Committee (MWFSAC) in 1997 to develop standards or guidelines related to metalworking fluids. In its final report in 1999, MWFSAC recommended that the exposure limit be 0.5 mg/m3 and that medical surveillance, exposure monitoring,
system management, workplace monitoring, and employee training are necessary to monitor worker exposure to metalworking fluids.
So there is a movement to dry machining for both economic and safety reasons. One of the biggest concerns in dry machining is the removal of chips after machining. Cutting fluid not only cools and lubricate but it also washes away chips. With dry machining, alternatives must be considered and one is the use on an integrated compressed air removal
system. These systems can minimize cost of air using air amplification technology such as Nex Flow Air Mag® Nozzles and standard Air Nozzles for chip removal. Their design allows them to remove chips eve when placed at some distance away due to their laminar air flow.

Safety is immediately improved with dry machining whenever the use of coolant and/or lubricant is eliminated or at least decreased. Advances in the types of coatings applied to cutting tools have been the major factor in improving the feasibility of dry machining to improve tool life in dry machining applications. What is left is lubrication where needed and cooling. With cooling several types of systems are being developed using cryogenics, and even heat pipes, some which involve the use of costly and environmentally unfriendly refrigerants and also costly system designs. The use of vortex tubes is for cooling is a relatively low cost viable option. Tests have shown that vortex tube based air cooling provides a highly efficient heat removal mechanism for metal cutting and delivers thermal cooling performance very much comparable to traditional liquid coolants without the inherent chemical exposure risks to machine operators and harmful impact on the environment. The tool life is very much unchanged and the surface finish quality of workpiece shows no significant change in comparison to liquid cooling. The Nex Flow Tool Cooler was developed for these applications. When lubrication is required the ideal would be to minimize the amount of lubricant needed. Using a vortex tube to cool the lubricant just before it is applied can reduce the amount of lubricant used as much as 20%. The patented Nex Flow Mist Cooler which incorporates vortex tube technology was created for these applications where some lubrication is needed.

Both the Tool Cooler and Mist Cooler are low cost alternatives to use in dry machining.

In summary….

Dry Machining Options

Cryogenics and Micro Lubrication – effective but costly designs
Heat Pipe – limited in cooling effectiveness but low cost
Tool Cooler or Mist Cooler with vortex tube – effective and low cost

As counter-intuitive as this may be, it can be true.

For example, if you use a horse drawn carriage to take you from Chicago to New York you will save a tremendous amount of energy – virtually no gasoline, and most likely a big contribution to the cleaner air. However, it will take many days longer to arrive, added cost of hotels and meals (which takes up energy for the stay, the preparation of food, etc.) and the “downtime” of not being at your destination earlier.  As silly as this example may first appear, it is actually quite sound!  When focused only on “energy cost” one can fail to appreciate the benefit the extra energy adds to productivity and output.

70% of usable compressed air (after leaks which is an entirely separate issue) is still used for blow off applications simply because more energy efficient blowers just cannot do the job.  What is the point of saving energy if you slow down production?

Other factors that are important in energy reduction is the impact the reduction has in:

1. Factory output
2. Maintenance cost issues
3. Capital Cost
4. Space
5. Personnel Cost
6. Replacement Cost

Factory Output: There have actually been cases where blowers have replaced compressed air blow off and then, the compressed air put back because the blowers lacked the energy to perform the job and output decreased. More often, blowers have been put in and then compressed air blow off “added in” after for the same reason. Both system would be running when the compressed air blow off would normally be enough to be effective. So now you have a blower system AND compressed air blow off. The energy use is either the same or maybe even higher!   Generally factories want to increase output, not reduce it.  The increased output utilizing compressed air should be considered as it can more than offset perceived energy savings.

Maintenance Cost Issues: Ever wonder why air tools are so popular over electric tools? One factor is maintenance cost. Compressed air operated devices are simpler, more rugged and last longer and subject to much less maintenance than most other options. One example is vortex tube technology used for spot cooling and especially for cabinet enclosure cooling and cooling industrial camera enclosures. We are certainly not saying that vortex tube cooling for cabinet enclosures apply everywhere but, in a very dirty and/or humid environment the increased energy use using compressed air can, and are, in those situations easily offset in high maintenance cost of just the time and material cost of replacing filters, not to mention replacement cost of air conditioning equipment in those kinds of environments. In very dirty environments vortex tube operated air conditioners also keep out dirty air, and keep internal components “clean” extending controls lifetimes and replacing costly controls.

Capital Costs: Compressed air operated equipment is simpler and typically much lower cost – period. And they last longer too.  Capital costs of any equipment amortized over a reasonable period of time need to be considered against energy costs.

Space: The footprint of the equipment doing the job of blow off, drying, cooling, or moving is important. It is important in the opportunity cost in utilizing the space, and for worker accessibility. Compressed air operated equipment is smaller, lighter, compact and rugged.

Personnel Cost: Labor is becoming more costly as time goes on. A potential qualified labor shortage is looming (despite the rise of machines). So anything that will save on labor is a factory cost saving. Compressed air nozzles, air knives, air operated conveyors, vortex tube technology is all essentially maintenance free. When considering the cost of alternative energy, consider the added labor cost as a major factor, not only for the time taken up by the person, but the cost of other things related to production “not” being done.

I am sure many people, especially those touting blowers as the ultimate solution to compressed air will disagree but I am certainly willing to meet and discuss further. I will bring my car and they can bring their energy saving horse and buggy – but please, do not keep me waiting!

Nex Flow manufacturers quality, and economical, specialized compressed air solutions for blow, off, cooling, drying, and moving with representatives worldwide. www.nexflow.com

Vortex Tube operated cabinet enclosure coolers such as the Nex Flow Frigix-X Panel Coolers operate utilizing compressed air wherein one end gets hot, and the other end gets cold. They find applications in particularly dirty environments and hot and wet factory climates.

Because of the rough environments they are subjected to, construction materials are pretty necessary. Some manufacturers utilize stainless steel with the vortex tube (cold temperature generating portion) and then packaged it in an aluminum housing and assembly, usually not anodized. So after a short time, the appearance of the aluminum, especially if not anodized in such environments, look pretty deteriorated.

But it is mainly in hot and humid environments where the combination of stainless steel with aluminum can be a problem due to the possible effect of galvanic corrosion between these two very dissimilar metals. Due to this corrosion effect, I have personally seen a vortex-style cabinet enclosure cooler with a big gaping hole in its aluminum housing.

So if choosing vortex tube operated cabinet enclosure coolers, it is a good idea to check what they are made off. Nex Flow makes them from stainless steel. The vortex tube, housing, and attachments are stainless to avoid this corrosion issue. Stainless steel will obviously hold up much better than aluminum in a nasty factory environment.

Nex Flow manufacturers specialized compressed air products for blowoff, cooling, and moving c/w quality accessories for controlling, monitoring, and filtering compressed air.

This question comes up occasionally and surprisingly the answer is yes, but not like how you may think. One explanation put forward is that this happens because normally a liquid used has a vapor pressure. You reduce the hydrostatic pressure below this vapor pressure in the center of the vortex tube causing the fluid to flash and form a vapor bubble along the central axis in the vortex. However, this bubble will collapse as it exists the cold end. If there is any temperature difference at all, it may be hardly measurable.

Tests that actually have been done show that a temperature difference can be created using liquid instead of gas but, it will heat up, not cool.

R.T. Balmer did experiments with water as a working fluid in a vortex tube [R. T. Balmer, ASME J. Fluid Eng.110, 161 (1988)]. The water inlet water temperature was about 20 degrees C, and the hot end got as high as 50 C, while the cold side achieved a temperature of 25 C (Still heated up!).

So using a vortex tube with liquids for heating may have some potential as yet to be identified…… maybe!

 

FEATURED PRODUCTS

[one][one_third][image src=”https://www.nexflow.com/wp-content/uploads/2017/08/Vortex-Tubes-Side-by-Side.png” size=”” width=”” height=”” align=”center” stretch=”0″ border=”0″ margin_top=”” margin_bottom=”” link_image=”” link=”https://www.nexflow.com/products/vortex-tube-industrial-cooling/vortex-tubes/vortex-tubes/” target=”_blank” hover=”” alt=”” caption=”Vortex Tube” greyscale=”” animate=””]

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Nex Flow Air Products Corp. manufactures vortex tubes using compressed air and have done special designs using other gases for special applications. They are one of few companies today that continue to do extensive research into vortex tubes. Nex Flow welcomes inquiries into possible new applications.

NEMA and IP Classifications Equivalency

l and electronic enclosures while Europe and many other countries utilize IP classifications. This often causes some confusion. We found a great chart from Siemon that do IT infrastructure solutions what has a very concise equivalency chart.

This reference chart will be useful when choosing

https://www.nexflow.com/cabinet-enclosure-coolers/

for air conditioning control panels anywhere in the world.

Nex Flow Air Products Corp. manufacturers specialized compressed air products for cleaning, drying, blow off, moving and cooling applications. They lead in vortex cooling technology development. A major application for vortex cooing is for electrical and electronic enclosures, especially is very humid, hot and dirty environments where regular air conditioners would entail much higher maintenance costs and shorter life.

NEMA and IP Classifications Equivalency

Determining the Cost of Compressed Air

When companies are trying to estimate the cost saved using compressed air saving technology such as air saving nozzles, compressed air amplifiers, etc. it is important to know your real compressed air cost. A typical figure used is 30 cents per 1000 cubic feet of air but it can be more in some cases.

To calculate the cost of compressed air in your facility, use the following formula:

COST =

(shaft HP) X (0.746) X (operating hrs) X ($/kW-hr) X (% time) X (% Full Load HP) . Motor Efficiency

The compressor “Shaft horsepower” is frequently higher than the motor nameplate horsepower so you need to check the equipment specification),

Percent time = percentage of time running at this operating level,

Percent full-load shaft HP = Shaft HP as a percentage of full-load Shaft HP at this operating level,

and

Motor efficiency = Efficiency of the electric motor at this operating level.

Determining the Cost of Compressed Air Example

Let’s assume a manufacturing facility has a 100 hp compressor (which requires 110 Shaft HP) that operates for 6,000 hr annually. It is fully loaded 85% of the time (motor efficiency is 95%) and unloaded the rest of the time (using 25% full-load shaft HP and motor efficiency is 90%). The location electric rate is $0.10/kWhr.

Cost when fully loaded will be:

COST = (115 HP) X (0.746) X (6000 hr) X ($0.10/kWhr) X (.85) X (1.0)/.95 

= $46.056.00

Cost when partially loaded:

COST = (115 HP) X (0.746) X (6000 hr) X ($0.10/kWhr) X (.15) X (0.25)/.90

= $2,145.00

Annual energy cost = $46,056.00 + $2,145.00 = $48,201.00

Cost per hour = $48,201.00/6000 = $8.00 an hour or $0.13 per minute.

If this compressor generates 425 SCFM which is likely then the cost per cubic feet is:

1000/430 X $0.13 = $0.30 per 1000 cubic feet.

Efficient operation of the compressor is very important to minimize energy cost as well as reducing leaks, and utilizing energy efficient auto drains, filters, tools and air amplifying blow off products and other items to optimize compressed air use.

Nex Flow manufacturers compressed air products for efficient blow off, cleaning, drying, cooling and moving and can assist in the efficient use of compressed air

Compressed air operated air knives are ideal for replacing rows of nozzles or drilled pipe used in blow off applications. What to look for and installation tips are explained here. Nex Flow Air Products are specialists in compressed air applications for blow off, cooling and moving.

Using Compressed Air Operated Conveyors for Conveying

In utilizing compressed air operated venturi systems such as Nex Flow’s® Ring-Vac®Air Operated Conveyors, you size the unit based on the size of the parts being conveyed.

The general rule is to have the inside diameter of the unit to be double the maximum size or dimension of the parts being conveyed. In this way there is little chance of the parts clogging the unit.

However there are exceptions. One customer for example, had to move a metal rod from one part of the factory to another. This enterprising company utilized the Nex Flow® 2″ Model 30004 Ring-Vac®. The company fed a 1” diameter but 4″ long metal rod into the unit and used the venturi to convey the rod from one end of the factory to another reducing handling time dramatically.

The rod was made to fall onto a gravity feed slot which feeds the rod into the Ring-Vac®. Air is conserved by turning it on only when there is a rod to feed and this is controlled by a sensor. The rod is then literally shot 15 feet up to the ceiling area in a plastic tube connected to the Ring-Vac®. At the ceiling, the feeder tube is then angled about 2 degrees downward where the part is then gravity fed in the tube, across the ceiling, to the other end of the factory which of course, requires no energy.

The part drops out into a bin at the exit of the tube where it is manually picked up for further processing at another machine station. Intermittent applications such as this are ideal for such technology since the unit is low cost, compact, with no maintenance and operates instant on and off only as needed. The use of gravity to feed the part from one end of the factory to the other was brilliant.

Can you think of other applications like this??

Nex Flow Air Products Corp. manufacturers compressed air technology for blow off, drying, cleaning, cooling, and moving and constantly strives to improve their products’ performance and quality. Creative ideas are encouraged and embraced!

Possible areas to address in a compressed air system to save energy are listed below. Some, or all may apply to your system:

1. Piping Design, redesign: Increase the diameter of the piping; reduce the length of the network; loop the network; limit elbows and bends. Check for and repair leaks regularly.
2. Install a system with several pressure values (multi-pressure systems or networks), either separate or connected to each other determined by what is required by the compressed air consuming equipment or application. Reducing 1 atmosphere (14.7 PSI) or bar pressure provides an energy saving of 8%.
3. Utilize the heat of compression: 90 % of the electrical energy consumed by a compressor is converted to heat. In practice, 60% of this heat can be recovered and used within a factory operation.
4. Consider automatic control of the compressed air production via a variable speed compressor or an automatic control of all the compressors according to need. Average 15 % savings with automatic control (from 5 to 35 %). Not all systems will benefit but a compressor supplier can assist in evaluating what is appropriate for your plant.
5. Reduce the air inlet temperature to the compressor: 1% consumption savings are obtained every 3 degree C reduction. Check from where the air intake draws into the compressor(s).
6. Replace compressors with new and better machine(s) with lower specific energy consumption (more compression stages) that may be more suitable to the requirements of your system.
7. Use “leak-loss free” condensate traps. A high-performance network allows for a maximum pressure loss of 7 PSI or 0.5 bar throughout the line.
8. Enhance and check pressure regulating valves, filters, lubricators, driers and condensate traps for quality products that minimize pressure drop and leaks.
9. Dry off and filter air moderately as needed abut not more. Too long a drying or too fine in filtering leads to unnecessary overconsumption of energy as much as 6%.
10. Monitor compressed air use at key points.
11. Design proper storage capacities to allow operation with higher output of compressors and to avoid unexpected switching on or off.
12. Install control equipment such as flow meters and air meters, current meters, and pressure gauges.
13. Replace leak generating equipment parts, cracked air hoses, old sticking connectors and valves, etc.
14. Use energy saving, engineered blow off nozzles and air guns, amplifiers and air knives.
15. Use sensors and solenoid valves to turn off compressed air to machines when not in use.
16. Divide the network into areas with pressure controls or appropriate isolation valves. Close the network areas when not used.
17. Place storage capacities next to machines with high variation in air required.

USE COMPRESSED AIR WISELY!!

Nex Flow Air Products Corp. manufacturers compressed air technology for blow off, drying, cleaning, cooling, and moving and constantly strives to improve their products’ performance and quality and to educate in the optimum use of, and in applications of compressed air.

It is popular now to use the term “engineered” air nozzle for compressed air nozzles used for blow-off applications. But what is an engineered nozzle? The original close air-operated engineered nozzle is a cone shape that draws in surrounding air utilizing the “Coanda” effect and converts pressure to flow by removing atmospheric air and the nozzle’s compressed air. Copies and different physical sizes abound in the marketplace, but are they really engineered? The size, the angle of the hole, and even how the air flows inside and out of the air nozzle are essential. It can be easily proven by taking two similarly looking cone-shaped nozzles from different manufacturers and testing them side by side. Even if they look similar on the outside, they may perform dramatically differently, perhaps being louder (or quieter) and the other more (or less) powerful. A truly engineered version will consider inside and outside flow characteristics. But these cone-shaped designs generally provide the most “flow” amplification.

For most applications, however, force is more important, so a high ratio of force/air consumption (CFM) is essential. The “bullet” shaped finned nozzles with holes in between the fins seem to provide this optimum force/cfm better than the cone-shaped versions. The bullet shape still entertains the Coanda effect to accelerate outside air to produce more flow. As with the older designs, the number of holes, their size, overall shape, and fin design are essential but also the way the air flows on the inside. Copies of these bullet-shaped nozzles have also appeared but rarely perform even close to the original designs because they are poorly copied and not engineered. As with the cone-shaped styles, this can be quickly confirmed by taking two similar-looking nozzles from two manufacturers and comparing the force each produces at the same line pressure. The copy rarely does as well.

What Is An Engineered Air Nozzle Really!!

A few years back, so-called Laval effect nozzles, which have the compressed air exiting the nozzle using an hourglass-shaped exit to accelerate the exiting compressed air, appeared on the market. However, it is questionable whether they are any more practical for a higher force/cfm ratio than nozzles using the Coanda effect, incredibly if not close to the target of the blow-off. Noise is another factor with this style of the nozzle.

A bullet-shaped nozzle developed by Nex Flow Air Mag nozzle series is patent pending where the air exit nozzles are oriented in such a way as to increase the force/cfm over the best competitive nozzle found by about 10% and make it more effective at a greater distance. This is truly an engineered nozzle, and all factors, both inside and out, are considered. At the time of this writing, the available Nex Flow Air Mag sizes are 1/4″, 1/2″ but 4, 5, and 6 mm small nozzles are pending. A 1/8″ adaptor for the 6 mm nozzles will also be available.

So when looking at engineered nozzles, carefully research the actual force/CFM, at what distance and line pressure the specifications are taken, and the distance of their effectiveness to make sure it is genuinely engineered and will be suitable for your application. Stay with brand names like Nex Flow to assure quality and be wary of copies.

Nex Flow Air Products Corp. manufactures compressed air technology for blow-off, drying, cleaning, cooling, and moving and constantly strives to improve its products” performance and quality.

 

FEATURED PRODUCTS

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Compressed air is used extensively for blow-off, cooling, and drying applications as blowers are not always powerful enough or have other disadvantages in the specific application. Since compressed air is a costly power source factories should reduce the compressed air cost by utilizing high efficiency engineered nozzles, air amplifiers and air knives. This technology is designed in such a way that it uses the compressed air to entraine and accelerate the surrounding air to deliver the same mass transfer effect as the single large opening in a standard nozzle, and even proving a better and more effective force because it reduces turbulence by providing laminar flow over a greater distance. The side effect is not only much less energy use, but also dramatically reduced noise levels.

However it is still very prevalent in factories to just use open tube and pipe for blowing compressed air.  Even a small tube can exhaust a great deal of air wasting energy. The amount of air can be determined with a mathematical formula A more extensive formula is dependent on temperature and the condition of the inlet air, but by assuming standard conditions we can use the following simplified equation:

14.485 x D² x (psig + 14.7) = “X” SCFM

Where: 

• D is the inside diameter of the opening in the pipe or tube in inches
• PSIG is the compressed air gauge pressure in pounds per square inch
• SCFM is the resulting flow rate in standard cubic feet per minute

Let’s assume we have just a small copper tube with an opening of 1/8 of an inch, not an uncommon site in blow off operations with compressed air at 80 PSIG.  Using the formula it will consume:

 14.485 x (.125)² x (80 psig + 14.7) = 21.43 SCFM

Cooling Industrial Cameras Nex Flow

Industrial cameras that are in very hot environments can be cooled by several means

• pure compressed air
• water
• peltier coolers
• vortex tubes

Pure compressed air can add up to a large running cost due to the cost of compressed air, especially sine the air is going to a hot area, and the compressed air itself may be warm.

Water cools better than compressed air but it has its share of costs due to the flow though relatively small lines, heating up to high temperature and producing scale problems, risking shut down and downtime.

Peltier coolers may be find for computer CPU’s but may lack the necessary cooking power for an industrial application.

This leaves vortex tubes as a reliable option – they can produce the necessary cooling effect, no scaling problems to be concerned about, and because vortex tubes produce cold air from regular compressed air (even a warm air supply), they use far less energy than compressed air by itself.

Cooling Industrial Cameras Nex Flow

The important consideration is to assure the compressed air is clean – that adequate filtration removed any water and oil and dirt particulate. As long as the air is kept clean, you can have years of relatively maintenance free and trouble free cooling of your industrial cameras.

Nex Flow Air Products Corp. manufactures specialize compressed air technology for cooling, moving, drying, cleaning and blow off and also offers unique filtering technology for compressed air systems that have problems with moisture in their air lines.

 

Galvanic corrosion and materials

Galvanic corrosion occurs when two dissimilar metals come into contact. It is also necessary for there to be moisture, but it is rare to find an environment without moisture. I still remember visiting a factory and seeing a competitor’s Cabinet Enclosure Cooler (using vortex tube technology) with a big hole on the aluminum cover, obviously caused by some form of corrosion. While the unit was still functioning, this gaping hole made dirt buildup inside the system a definite probability of shortening the life of the unit which, if it used proper materials, or at least anodized the aluminum could last 20 years.

Air blow off products such as air knives, and amplifiers use (usually) aluminum or zinc. Air knives in particular are normally made of aluminum with steel, or stainless steel screws. The further apart the different metals that are matched together are, in terms of relative potentials, the greater the possibility of galvanic corrosion in a wet or humid environment. For example, stainless steel in contact with copper is less likely to be a risk than when it is in contact with aluminum or galvanized (zinc coated) steel. Seawater or salt laden moist air is more of a risk than contact with rain water or say water used for wash down in a factory. Vortex tube operated cabinet enclosure coolers are typically assembled using stainless steel vortex tubes since stainless is the most common material used for vortex tubes due to long life and durability. The surprise is that some manufacturers still, after many years, use aluminum for mufflers, sleeves and casings exposed to a potentially wet factory environment with a stainless steel vortex tube. As long as the environment stays dry, it is not a problem but if the environment is wet, or the enclosure cooler is used in a wash down environment such as in a NEMA 4 (IP56) area, then the risk of galvanic corrosion is much higher.

Anodizing the aluminum is one way to help prevent that from happening as it provides insulation to the galvanic action. But some manufactures of these units have not even done that.

Nex Flow Air Products Corp. uses stainless steel vortex tubes and stainless steel muffling, sleeves, etc. – no aluminum in their cabinet enclosure coolers (Panel Coolers) to avoid galvanic corrosion which can occur if the units are subjected to a humid environment or wash down procedures. Their NEMA 4 (IP 56) units are stainless steel for NEMA 4-4X environments.

What also comes into play is the surface area of each material used. For example, if there is a large area of aluminum and a little stainless steel screw, there will not be much of a problem. Aluminum air knives for example can have stainless steel screws and the galvanic action remains minimal. Nex Flow anodizes their aluminum material to be extra cautious. Most compressed air operated air knife producers however do not anodize. (The near term negative effect of a factory environment on non-anodized aluminum is another topic.)

To keep the aluminum/stainless mix acceptable, the stainless part should be small and the aluminum part large, and of course, keep them dry and away from a humid area. Better still, either anodize the aluminum or just do not mix the materials.

Nex Flow Air Products Corp. manufactures compressed air operated products for blow off, drying, cleaning, cooling and moving along with specialized pneumatic technology to reduce noise, energy use, and to improve the compressed air productivity in a factory environment.

Three steps for noise control in compressed air blow off and exhaust. Noise from compressed air can be very loud and damaging, so reducing noise is important.

Three steps should be taken where ever compressed air is exhausted, whether from cylinders or when used for blow-off and cooling applications.

1. Mufflers and Engineered Nozzles: Compressed air used for exhaust, typically from a cylinder, should have exhaust mufflers. Compressed air used for blow-off or cooling should utilize engineered blow-off nozzles that reduce noise levels. There are a few different designs on the market claiming to be the best, but the ones that perform optimally tend to be those that use a Coanda profile to entrain surrounding air along with the compressed air released, basically converting pressure to flow. This does three things… pressure is converted rather than lost as pressure drops, noise levels fall dramatically, energy consumption is reduced, and a laminar flow is maintained at a greater distance than from an open pipe, tube or hole so the nozzle or other blow off device is effective at a much greater distance.
2. Velocity: Sound level is proportional to the velocity of the compressed air flow exhausted. In fact, the sound level is proportional to velocity by a factor to the power of 8.
   Sound Level ∞ Velocity8
   Exhaust mufflers will take this into account. Once blow-off nozzles or other air-saving/noise reducing blow off products are installed, the velocity can be reduced by cutting back on the pressure at that location to the level where it accomplishes its job and then kept at the level. This minimizes noise levels and also saves energy.
3. On-Off Control: Finally, you should use one of the key advantages of compressed air – that it can be stored and used on demand. Utilizing PLCs that integrate sensors along a production line can turn the compressed air supply on and off as needed. When the air is not used, there is no noise, and further energy savings are realized.

 

FEATURED PRODUCTS

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So next time you are in the factory – “listen” then “look”. Every exhaust can be addressed to reduce noise levels at a relatively low cost with a quick return on energy saving and improving your plant environment.

Nex Flow Air Products Corp. manufactures engineered nozzles and other blow-off products and can advise on the best item to use for any particular application and offer consultation for end-use noise and energy management.

Hydraulics vs Pneumatics which to use

The two types of fluid power are similar in that both use a fluid to transmit mechanical energy and they also use similar terminology, symbols and components.

Hydraulic systems need a pump. Pneumatic systems require a compressor although compressed air is first stored in receivers/tanks before being transmitted for use. Both systems use valves to control the force and velocity of the actuators, which are also similar to each system.

The biggest difference between hydraulics and pneumatics is the medium itself and the capabilities of those mediums.

Liquids are actually slightly compressible. Hydraulic oil, as a guide will compress 0.5% for every 1000 psi that is exerted. For most applications however, liquid (usually oil) in hydraulics can be considered incompressible. If you push a large quantity of oil into a fixed volume, pressure will rise until something gives way, and this will happen instantly. The advantage of liquid being used to transmit mechanical energy is that the effect is rapid and negligible energy is lost to compression. However, the downside is more difficulty to move the fluid through valves, components and plumbing. Restrictions to flow of a liquid creates higher resistance and energy loss than compared with pneumatics. The restrictive nature of oil is compensated for by using properly sized components matched to handle the flow.

Hydraulic liquid has a high power density. Running a hydraulic system to 10,000 psi has little detrimental effect on performance compared to running compressed air to even 300 psi. Normally pneumatics runs at somewhere between 100 to 120 psi gage pressure. Air compressors are limited to the amount they can compress the air, and even with multi-stage compression, a lot of energy can be lost to heat. A great deal of effort is made to recover much of this heat to use elsewhere.

Hydraulics vs Pneumatics which to use

However, compressed air can do things that oil simply cannot. The compressibility of air can be an advantage, because when compressed air energy is released, it expands very quickly. Because the volume of air that can be moved though pneumatic valves and actuators is so high, especially when pressure drop is considered and properly accounted for, the speed of pneumatic actuators can be very fast. Pneumatically actuated machines are quick and are great for automated processes in manufacturing and assembly as a result. Pneumatic applications can still produce thousands of pounds of force, although hydraulic applications can produce thousands of tons. For lifting extremely heavy load or moving very heavy loads, hydraulics is a better choice. Compressed air actuators can become jerky or spongy as the compressed air pressure fluctuates with cylinder movement or load changes. In general, a much larger pneumatic cylinder is needed to obtain the same force that a hydraulic ram can produce. But then again, do you have to move hundreds of pounds or thousands of pounds?

In terms of energy costs pneumatics is more costly than hydraulics, mainly due to the amount of energy lost through heat production while compressing air Pneumatics offer a higher operating speed of its components mainly because of air compressor flow rates as air is very agile and can flow through pipes very quickly and easily with little resistance, while hydraulic oil is a viscous substance and requires more energy to move. Also in pneumatics, cylinders and valves can dump their compressed air straight to the atmosphere when they need to change direction or alter their state quickly, compared with hydraulics where the oil must be routed back to the reservoir.

Pneumatics offer a very clean system, suitable for food manufacturing processes and other processes which require no risk of contamination. Hydraulics is generally not used in these environments due to the risk of hydraulic oil leaks from faulty valves, seals or burst hoses.

The mathematics used in applying hydraulics and pneumatics is different. Hydraulics is not concerned with compression ratios, and pneumatics is not concerned with pressure compensation.

So from the above, the system you chose will be determined primarily by the load you need to address in your operations, the speeds required for efficient production output, the application, and energy considerations.

Nex Flow Air Products Corp. manufactures compressed air products for blow off, drying, moving and cooling and accessories to optimize compressed air systems.

This of course is my educated opinion only but I think it is reasonable. When you buy a new home from a builder, would you buy the furniture from the same builder? In fact people do in some cases get furniture with a new home but the home builder does not make the furniture. That is because the home builder is an expert in making homes – the furniture an expert in making furniture.

Similarly in industry, when a production line needs to “get something wet” and then “dry”, a spray nozzle manufacturer will be an expert in spray nozzles while a compressed air nozzle manufacture (used to dry) is an expert in air nozzles. They are very different technologies with a very different focus and thinking behind their use. Many spray nozzle manufacturers have come out with air nozzles which are usually knock-offs of other manufacturers and in many cases not very good ones. That is because compressed air is a totally different technology. The air nozzles may be less energy efficient and certainly have a much smaller range of choices, so a less than optimum solution is obtained. Similarly, some compressed air nozzle manufacturers have come up with spray nozzles with the same contraints. They have a smaller range of choices possibly leading to a less than optimum solution and again, with a different background and knowledge in their application and product development.

No one can be an expert in everything. There are good distributors in the market place that can supply both technologies who offer spray nozzles of one make and air nozzles of another, giving a wider choice and the better chance of a more productive and energy efficient solution.

Sometimes it is wise to shop around, whether for your home, or for your factory.

Nex Flow Air Products specializes in the manufacturer of compressed air products for blow off, cooling and moving.

Compressed Air Amplifiers are also called “Air Movers” for a reason – they can be used for moving a large volume of air. For examples, a properly designed 2″ Air Amplifier will amplify approximately 15 times the input air supply. That means it “moves” from the suction side 15-1 = 14 times the air consumption. That is a decent amount of air! This lends itself to venting applications.

Where they tend to be used, is where it is sensible to sue compressed air instead of electrically operated venting units. Past applications include:

1. Boosting Suction on Fume Removal Systems – large multi station fume extracting stations, if not designed properly or even if they are, if station equipment is moved around due to production changes, may result in some stations not having enough vacuum to draw in fumes due to pressure drop at the entrance. An air amplifie at the entrance can overcome that pressure loss.
2. Welding Robots – when welding, fumes are produced on robots and compact size and light weight of the air amplifiers makes it ideal to use to draw away the fumes produced by the welding that could interfere with sensors or otherwise impair the process.
3. Clear the Steam in Quenching – in the steel industry where water is used to quench or cool produces a great amount of steam when water is poured onto the metal. This interferes with sensors and visual observation of the process. Well places air amplifiers draw away the steam.
4. Cooling Personnel – when personnel have to work in hot areas, and space is an issue, the compact portability of the air amplifiers is ideal to have them cool.

Air Amplifiers are light weight, compact and portable so any application where that can be an advantage is ideal for their use, especially if the use is intermittent minimizing the real energy cost of compressed air.

Nex Flow Air Products producing air amplifiers and other air amplification technology for venting, blow off, cooling and moving.

Definition of Coanda effect is: the tendency of a jet of fluid emerging from an orifice to follow an adjacent flat or curved surface and to entrain fluid from the surroundings so that a region of lower pressure develops.

The Coanda Effect was discovered in1930 by the Romanian aerodynamicist Henri-Marie Coanda (1885-1972). He observed that a steam of air (or a other fluid) emerging from a nozzle tends to follow a nearby curved surface, if the curvature of the surface or angle the surface makes with the stream is not too sharp. For example, if a stream of water is flowing along a solid surface which is curved slightly from the stream, the water will tend to follow the surface.

The Coandă effect has important applications in various high-lift devices on aircraft, where air moving over the wing can be “bent down” towards the ground using flaps and a jet sheet blowing over the curved surface of the top of the wing. The bending of the flow results in aerodynamic lift.

And of course it is used in compressed air flow amplification technology to create energy efficient and noise reducing air nozzles jets, amplifiers and air knives used in blow off applications. This has tremendous positive implications for compressed air energy reduction and to meet OSHA standards in compressed air blowoff.

Nex Flow Air Products Corp. specializes in the manufacturer os compressed air products for blowoff, cooling and moving to optimize energy use and safety with compressed air.

Definition of the Coanda Effect

Can water damage my compressed air

If left in a compressed air system can cause damage to the system and also contaminate your end product.

Water in your compressed air system will cause rust. This rust will mix with any oil from the compressor or lubrication system and any dirt particles that are introduced into the system through the inlet of the compressor forming a sticky mass that can clog pneumatic circuitry and stain or even pit finely finished surfaces. Microbes also grow within the piping system, feeding off the organic materials. That’s why the condensate in a filter drain often has a foul odor. So preventing water formation as much as possible, and removing water (and oil) when you can is necessary.

Normally after the air is compressed the air travels through an aftercooler which is just a heat exchanger designed to cool the flow of compressed air that exits the compressor discharge. The drain trap will remove condensed water. The operation of this drain is the first thing to check if you are having moisture problems. A failed drain will allow large amounts of water to enter the compressed air system. Optimally you would have a storage receiver in line just after the air compressors, to allow a place for the compressed air to cool and condense water. Any captured water can be removed from an additional drain on the bottom of the receiver.

Properly designed compressed air piping will prevent water from ending up in production machinery to a large extent. The piping should be sloped away from the compressor slightly. This way, any water that condenses out as the air cools will flow down to the lowest point, where a drain should be located. Connection points feeding production machines should be located on the top of the main distribution piping, so as prevent water draining into critical locations.

Properly sized air dryers on your system will help prevent free water from forming in your piping. However, the piping design should be such that it minimizes any trouble that might be caused it the dryer fails or is off for any reason and also to address outside air that could get drawn int the system.

Any water removed is contaminated with dirt and compressor oil and should be disposed of correctly so as not to pollute the environment.

Water will rust piping and receiver tanks so drains must be in good working condition. Tanks should be be inspected regularly to ensure the rust pitting has not created a safety hazard with the tank.

In cold climates, water in the air lines can freeze and expanding ice can plug and crack pipes if wet air is directed outdoors in freezing conditions.

Because water is a universal solvent, it will wash away beneficial lubricant in air compressors and in compressed air powered tools, causing early machine failure or excessive wear.

If water contaminated compressed air blows onto the end product though air nozzles or air knives, it will both wear and possibly clog the blow off product and of course contaminate or otherwise negatively effect the end product.

It is for the above reason that it is a good idea to use point of use filter before any blow off application. Another area where point of use filtration is ideal would be before actuator valves which are sensitive to water and dirt contamination.

For the above reasons and more, it is important to minimize water contamination in your compressed air system.

Nex Flow manufacturers compressed air products for blow off, cooling, and moving and can assist you in your compressed air applications.

Keeping Camera Lens Clean

Solving pneumatic challenges globally – NexFlow – President

Compressed Air Considerations for Blow off and Cooling Applications

Despite the push by blower providers to convert compressed air blow off to blower operated systems, the fact is 70% of compressed air is still, on the average, used for blow off applications. Despite higher energy costs, the only thing blower companies even consider, compressed air blow off remains reliable, the only maintenance is the compressor and filter system, is compact and generally more powerful and can do the job a blower cannot. When blower companies compare against compressed air cost they assume the compressed air is always at high pressure (many times it is not), and constantly in use (when in fact it is generally not). Blowers cannot go on and off on demand, while compressed air can. When you take these two things into consideration (lower pressure and on-off operation), the cost of using compressed air can actually approach that of using a blower in some applications. Add the benefits of a smaller footprint, near zero maintenance and long life it is no wonder compressed air is still used extensively for blow off and cooling applications.

But that does not mean the product used should not be carefully considered. It is natural for a company making blowers to push their blowers and be biased towards their use. Similarly a company that makes only compressed air nozzles, would be biased toward using their nozzles. Apart from nozzles however, whether round or flat, there are other products available for blow off such as air jets, air amplifiers, air knives and air wipes. So let’s look at what is available for compressed air blow off and cooling and, when to use them. We have:

Engineered Air Nozzles: air nozzles designed and engineered in such a way to entrain surrounding air with the existing compressed air are the most efficient to use for general blow off applications. They vary in a wide variety of sizes and air exits in such a way to give a narrow or wide blow off profile. Nozzles can be arranged in a row, usually on a manifold, to cover a range, and spaced to give full coverage based on the flow profile. The distance you place these rows of nozzles from the target will depend on the flow profile of the nozzle. Often rows of flat nozzles are arranged so that the distance from the target is less sensitive.  Regardless, the most powerful force from the nozzles will tend toward the center of each nozzle.  A nozzle can also be used to cool a small part. But for cooling larger parts other alternatives (see below) are better.  Nozzles come in a wide variety of designs. You need to consider three things – air consumption, force produced and profile of the flow. Air guns usually prefer nozzles with a narrow flow profile for example.

Air jets: jets are often called small air amplifiers, and entrain surrounding air from the back of the jet and mixed with compressed air converting pressure normally lost into flow. Air jets consume as much energy as a nozzle but instead of a point of force, it produces an output more like a “hand”. This can be very useful especially in part ejection of larger parts. As an example, to properly eject a part off a conveyor you normally need two nozzles to insure the part is ejected in the right direction. That’s two nozzles each consuming energy. It can be replaced with one air jet because the “hand” like blow off to control the direction of the ejected part. This essentially cuts energy use in half as well as eliminating a connection. Cooling a small part is also more efficient using an air jet than a nozzle.

Air Amplifiers (or air movers): air amplifiers are big air jets. Air is entrained from behind and mixed with the compressed air, converting pressure to flow. These units are incredibly efficient flow amplifiers but do not produce the same level of force as nozzles. But if that high level of force is not required, these are exceptional products to use for blow off and cooling. A major application for air amplifiers is for cooling forgings, castings and other “hot spots” using minimal amounts of compressed air.  As an example, there was one application where aluminum cast parts were previously left to cool in open ambient air for 30 minutes. When an air amplifier was used on the parts the cooling time was reduced to one minute.  In another situation, in a steel factory, a one inch open pipe of compressed air was used to cool motors in a very hot area. When an air amplifier was added the compressed air was reduce by literally over 80% and the motor actually cooled “better”. Air amplifiers are also called air movers for a reason … they are used for venting of fumes, boost dust removal systems and even used as dust collection and mist collection on grinding operations, especially when portability and space are important factors.

Air Knives: compressed air operated air knives are generally used to replace rows of drilled pipe. As with amplifiers, they convert energy normally lost as pressure drop into flow. They do this with a very large drop in noise level. They are not as powerful as rows of nozzles but they do have the advantage of near equal force along the length of the air knife and full coverage. When blowing off a large area, the advantage of the equal and complete coverage of blow off often provides a far superior blow off than rows of nozzles and because of very high efficiency can even use less energy than rows of nozzles.

Air Wipes: these units are basically round air knives or split amplifiers (in two pieces) to blow off (or cool) extruded parts from wire to pipe. Some providers provide nozzles on a round manifold to do the same thing but again, do not have the same efficiency nor give the full coverage an air wipe does.  Air wipes are a better option and come in a wide variety of sizes.

One comment should be made here, as cooling is mentioned above using air amplification. There are applications for spot cooling where a Vortex Tube should be used instead. This is where the product provider’s expertise can advise the best solution.

In summary, there is more than one option for compressed air blow off or cooling depending on the application. Consider companies such as Nex Flow Air Products Corp. that make a wide variety of blow off products and spot cooling technology when addressing blow off and cooling (or moving or venting) so the optimal product is used. It’s not always just a nozzle which is best. Sometimes an alternative is better.

BE AWARE OF INDUSTRIES THAT MAY GROW OR DIE IN A MILLENNIAL WORLD

Sales people and marketing people need to be aware of the dramatic effect a change of generation can have on the marketplace and therefore their product or service.

Here is the classification of generations…..

Baby Boomer Generation – Born between 1946 and 1964

Generation X (Baby Bust) – Born between 1965 and 1979

Generation Y – The Millennial – Gen Next – Born between 1980 and 1995

Generation Z – Born between 1996 and 2010

Millennial preferences are having a destructive impact on several companies and industries already, because they are more careful with money, and have much different preferences than their parents.  Articles abound about how they are killing industries such as golf (don’t play), movies (they download), paper (environmentally conscious), cereal (eat health bars instead), certain retail brands (what’s in a name anyway), auto industry (don’t buy, they car share), and it goes on and on….

And why?  Simple! They had no say in creating the environment that has restricted their income and shaped their financial perspective. The 2008 financial crises did it all to create a uniquely thrifty generation focused on short-term rewards.  As one article I found puts it –it’s the “parent’s fault! They caused the financial crises.” Not only that, they were raised in a “bubble world of over protection and immediate satisfaction” and made very aware of environmental issues.

You need to be aware of industries that are affected by this generation as it begins to take over from Generation Y and as Boomers (albeit slowly) exit the work force. If you are in the paper industry or supply the paper industry… what has to change to adapt? How many auto plants will have to (maybe) close that will also effect feeder factories and their suppliers? It’s not just the electric car that can change things in the auto industry, it’s virtually the “potentially less volume” change that will affect the market.  Who do you supply to now?  What about the food industry? How is that going to change and how will their needs change?  And let’s not even start about automation and artificial intelligence!

As a start, any company providing goods and services should pay close attention to the industries that are, and will be more and more effected by millennial’s as they start to take over as the major market!

Industries that may grow or die

Some months ago I posted the above pic with a short comment but with little explanation of how it worked so I will explain it more now.

Extruded profiles come in many shapes and configurations but the Ring Blade air wipe made by Nex Flow is able to dry and clean these shapes due to its design. It produces an “amplified” air flow utilizing an annular “coanda” effect to create a powerful force of compressed air mixed with entrained air, basically converting energy that would normally be lost as noise and pressure drop into useful blow off energy. This lowers both noise levels and energy costs. In the above picture, the single Ring Blade cleans the complex extruded part easily instead of using many nozzles that would make setup more complicated.

The air flow is at a 30 degree angle to the extruded part and is able to get into corners to clean and dry. The unit is made in two parts held together by hinges so it can be opened to move or remove an extrusion if necessary such as in applications of extruded rubber where “bubbles” may form. Nice design for easy installation. Sizes from 1/2″ to 11″ internal diameters are standard but special sizes can be made. Materials range from anodized aluminum to 316L stainless steel or special materials on request.

If you have questions on the use of compressed air for drying, cleaning, moving or cooling contact me on LinkedIn or visit www.nexflow.com

(Ring Blade and Nex Flow are registered Trademarks for Nex Flow Air Products Corp.)

Packaging of goods has gone beyond simple containers, bottles and cans such as the one depicted in the picture above. This particular packaging of pet food needs to be dried after washing. With limited space and a concern for noise, and high maintenance costs, compressed air operated amplification technology is used over noisy, space inhibiting blowers. Compressed air amplification technology minimizes the use of compressed air significantly. Sensors can indicate when the packages on the conveyor stop coming to shut down the air use when not needed.

But most importantly, it is the flexibility of the compressed air technology which provides excellent drying with minimal space requirements. In this application, two air saving nozzles blow off the water trapped at the bottom inside cavity of the packages (see the two cone shaped air nozzles on the left) and then two air knives (see the two gold colored units at the top third of the picture) wipe off the rest of the moisture.

This approach dramatically reduces the need for a long conveyor and is extremely quiet – the air knives in particular. A minimal amount of compressed air is used and maintenance is minimal. The nozzles and the air knives are aluminum and anodized as non-anodized aluminum will deteriorate in finish quickly in such wet environments. The result is an efficient, effective blow-off, with minimal maintenance, minimal footprint, quiet operation, and rugged, long lasting construction.

If you need to address any drying issues, including complicated ones, contact myself or check out the website www.nexflow.com

THE HYDRAULIC COMPRESSOR History

In doing some research on developments in compressed air technology I came across a fascinating bit of Canadian history at:

http://www.coppercountryexplorer.com/2011/07/the-taylor-compressor/

Imagined and built by Canadian Charles Taylor, this amazing compressor supplied all the power for a mine for 15 years in the form of compressed air to operate everything – I mean everything. An amazing story on compressed air. Maybe compressed air can power the world……

Thank you www.coppercountryexplorer.com for the story!

Any questions on compressed air contact me!

Formal compressed air system audits are costly and can be quite involved,. Experts are available to do this with expensive equipment in very large factory operations. But what about smaller facility where the cost and time is hard to justify?

In this case a simple “Check the Line” walk for a visual check can both be adequate but informative. The person or persons would check items such as filters, piping structure and condensate drains for operation and especially leakage where up to 30% of air can be lost and wasted. A relatively low cost hand held ultrasonic leak detector can identify leaks. In choosing one you need to make sure it has a narrow ultrasound range so as to identify real leaks and quality head phones to drown our factory noise so you can “hear” the leak. (Walkman style headphones are great when working on your car but not for a factory environment.) Sealing identified leaks can save a tremendous amount of cost. Replacing worn out fittings and connections that leak save even more. Stuck automatic drains releasing air is another item to identify and repair.

The quality of the compressed air should be checked. Dirty air increases the frequency and cost of filter cartridge changes, and threatens production quality. If left unchecked it can lead to production downtime. If water is blowing out of air tools for example, then a serious check of the filter system should be made. The life of the tools will be negatively affected. Dirty and wet air blowing onto a product from an air nozzle detrimentally effects product quality.

Another thing to inspect is the piping system to identify high pressure drops. You can decrease pressure drops by re-configuring piping and looking at the system as to where, and how much air is used. You can then ensure that the facility has the right compressor for the job(s) being done. Depending on how and where the compressed air is used and how much it fluctuates, can allow you to determine if the appropriate type of compressor is used. Variable Speed Drive compressors for example may be appropriate and efficient for high fluctuating energy demands.

Demands on a compressed air system will change whenever there is a change to a manufacturing process in the use of compressed air. A simple “Check the Line” can determine if the system needs any adjustment to maintain optimal compressed air use.

Nex Flow Air Products manufacturers compressed air products for blow off, cooling and moving. If you have any questions on the use of compressed air please ask.

An efficient application for compressed air operated venturi’s like Nex Flow’s Ring Vac units ( see www.nexflow.com) is hopper loading. Whether it’s loading resin for a plastic molding process, or a hopper of bottle caps for a bottling machine or capping machine, such units have the following benefits:

Energy efficient because they are instant on-off using compressed air only when loading. Overall energy use is small.
Instant on-off also means immediate usage. Electric blower systems have to be started up, reach a steady state, then convey, then wind down – taking more time and energy.
Compact – significantly less footprint
Less noise in use
Virtually no maintenance
Some companies actually produce loading system incorporating venturi’s with level sensing feedback systems to start and stop the loading process as necessary.

One example where such systems can save is in loading caps into a hopper feeding a capping system. Often caps are loaded manually from small boxes. If the caps are purchased in larger containers (lowing cost), the venturi systems can load the caps quickly and with much less effort and time.

If you have any questions on utilizing compressed air for blow off, cooling, moving or drying, please ask.

In any good compressed air system there is a receiver which stores compressed air. One of the advantages of compressed air is that it is an “on demand” source of energy. When it is not needed, it can be immediately turned off. When needed, immediately turned on. Energy is stored in a tank.

This is a particular advantage in intermittent applications, whether it is for the demand of a pneumatic tool or machine or for blow off applications. By storing compressed air, you can utilize a smaller compressor and use less overall energy with adequate storage capacity.

The receiver volume may be calculated using the formula

t = V (P1- P2) / (SCFM) PA

where

V = volume of the receiver tank (cu ft)

t = time in minutes for the receiver to go from upper to lower pressure limits

SCFM = air flow (SCFM)

PA = atmospheric pressure (14.7 PSIA)

P1 = maximum tank pressure (PSIA)

P2 = minimum tank pressure (PSIA)

There are recommended tank sizes based on consumption demand. The demand should be “average” demand taking into account intermittent use. Much is made of the high energy cost of compressed air. But the fact that it can be stored and used “on demand” does offer advantages especially in intermittent applications such as blow off in packaging or part ejection applications where the air does not have be constantly on thereby reducing energy use significantly, in some cases even approaching the cost of electrically operated blowers without the additional maintenance costs, noise and added footprint they create.

A 100 cfm compressor with a refrigeration drier, operating for 4000 hours in a temperate climate, can produce about 2200 USgal of liquid condensate in a year! Failure to remove this moisture can result in condensation in the compressed air piping which leads to corrosion, and damage to pneumatic tools and instruments and early failure. In hot and humid environments it can even be more of a problem as hot environmental air can hold more moisture.

Water vapor will condense as it continues to cool travelling through the system as the temperature falls below the dew point. Condensed water can wash away the pre-lubricants on cylinders and valves, and even damage the end product, especially in blow off applications.

As compressed air exists a compressor, normally water is removed by first an aftercooler, then into a moisture spearator where much of the water condenses out, then though filters that remove loose moisture. The compressed air which still contains water vapor then travels into a drier to remove this vapor before going into a dry receiver to be drawn upon by the system. Driers range from a refrigerant type which lowers dew point to about 35 degrees F, and desiccant type that lowers the dew point to around minus 40 F. typically but can be made to lower it to minus 100F. Depending on the application and factory environment the appropriate drier type is selected. A viable argument can be made that desiccant type would be most appropriate since the compressed air with a dew point of 40 degrees F or lower would not be as corrosive to a system with a higher dew point – at least in a perfect system.

A perfect compressed air delivery system presumes that no outside air can get into it. However in reality there is rarely a perfect system and it is possible that humid air from outside the compressed air delivery system can get into the system so additional filtration at the point of use is utilized. If the delivery system is complex, there may be areas with moisture that was not or cannot be completely removed. Other reasons for air is having areas in the system where the air falls below the dew point causing condensation. Any number of reasons due to the type of equipment in the system, may allow moisture into the system. Some compressed air delivery systems are built up by expanding onto older systems and condensation problems previously not there, can result.

So it can be difficult to avoid the need for point of use filtration.

(As a side note, Nex Flow Air has a rather unique filter called a Super Separator to address serious water/oil removal problems at point of use. If of interest please contact at lesr@nexflow.com )

WHEN USING COMPRESSED AIR

While it is known that compressed air is costly to use, there are still things that happen on the shop floor that creates a great deal of waste. The key to maximum efficiency in the use of your compressed air supply is in the delivery and end use of your entire pneumatic system. Ways to maximize the use are as follows:

1. Check for leaks. 30% of energy loss is typically lost in air leaks. These are often ignored since, unlike liquid, air leaks do not make a mess. But they drain dollars. You can use the “soap and water” technique on fittings to check for leaks, or hand held leak detectors to find them and repair. And easy way to check if your system has major leaks is simply charge up your system, turn the compressor off, and see how fast the pressure downstream goes down. If it stays charged – no leaks.

2. Upsize your air hose. All air hose will have some pressure loss. Companies seem to have a great deal of small 8 mm tubing or ¼” hose around which is easy to move around but creates much more losses than larger tubing or hose. Obviously you need to check against the air consumption at the end, but if possible use a larger tube – 12 mm instead of 8 and larger hose, 3/8” instead of 1/4” and even larger if the demand side uses a lot of air. There are charts easily available on line that gives you the pressure loss is different sizes of hose and tubing to determine the best size.

3. Minimize the length. As with smaller diameter of tubing or hose, so will the greater the length increase pressure loss. So keep lengths as short as possible. If you have to go longer – use a larger diameter.

4. Lubricate tools. Use the proper type for each tool that promotes long life to the particular tool and does not damage parts like O-rings and other internal parts. A good in-line system should keep them working properly.

5. Do not lubricate blow off. When the air is used for blow off or cooling applications do not lubricate as this will only block the particular nozzle used. If the entire airline is well lubricated, use an oil removal filter upstream.

6. Use safety blow off nozzles. There are engineered nozzles, air amplifiers, and air knives on the market for blow off that will reduce the compressed air utilized as well as (most) meet OSHA standards for dead end pressure for safe operation and also to keep exhaust noise levels low.

Awareness of the above can go a long way towards saving energy, extending equipment life and providing a safe environment is the use of compressed air.

Compressed air noise can be responsible for up to 1/3rd of the noise in a factory operation. So controlling noise from compressed air is important. This can be achieved with the following three steps:

1. Use control devices such as PLC’s to integrate sensors along a production line to optimize the air pressure needed and to shut off the compressed air supply when not used. On-off control is also an excellent way to save compressed air energy.

2. Use the optimum pressure needed for each particular application and check those settings regularly to assure they are maintained. Excess pressure wastes energy and produces more noise.

3. Use noise reducing air amplifying nozzles, air knives, etc. for blow off and cooling applications. Open jets and pipe waste a tremendous amount of energy and produce a great deal of noise.

While not contributing very much to noise levels, compressed air leaks do waste a great deal of energy and a regular leak detection program should be in place as 30% of compressed air energy can be lost in leaks from piping and connections and fittings.

High velocity compressed air blow-offs are especially useful if parts don’t need to be “super dry” (as completely free of water) or if there is a requirement to remove “excess” water or other liquid from a part prior to final drying using another means such as hot air or radiant drying. They are also used when there is a benefit of leaving some residual liquid on a part as in the case of a rust inhibitor. There are parts that, under certain circumstances, can be completely dried using only compressed air as well. Compressed air for blow offs is best delivered by using specialized nozzles designed for use with air or by devices called air knives. These products “amplify” the flow of air to reduce energy costs. Regardless, in many facilities, compressed air is expensive and is often in limited supply. This is especially important as effective compressed air blow-offs consume a relatively large volume of air. This has caused many facilities to consider the use of blowers instead but in many applications, the blow-off performance is simply not adequate and blowers themselves have added maintenance costs and noise levels which can be detrimental to the working environment that offsets energy saving.

An effective air blow-off requires that the surface to be dried is relatively close to the blow-off nozzles. The velocity of air diminishes rapidly as the distance from the nozzle is increased. A distance of about 3″ from the nozzle to the part is a good target for drying parts completely using compressed air although some items such as air knives have been used up to12″ with adequate results although much closer is recommended. Access to blind holes and enclosed spaces is difficult but special blind hole cleaning devices can work in this case. After blow-off, if there is still a need for additional drying then other techniques need to be performed.

For all its limitations, compressed air blow-offs remain a valuable tool in reducing the load on other subsequent drying techniques. It makes sense that the any reduction in the amount of water or other liquid that needs to be evaporated or removed from a part by another method results in a faster, more reliable, and frequently less costly and more efficient process overall.

Compressed is a friendly and reliable energy source used for many applications but sometimes not enough thought is given to the “pressure drop” when using the air.   Pressure drop is the loss of pressure due to energy loss in transmitting the compressed air.  Often pneumatic machines will run slower or not at all and blow off products not work as well simply because the pressure drop is not accounted for.

For any application, you need to know the air consumption of the end product and to assure the supply line is large enough to be certain that he pressure drop is not too high, especially if the loss of pressure falls below the minimum required for the device using the compressed air.   There are two types of pressure drops: natural and unintended.

Natural loss occurs as the compressed air travels through  the airline once you know the air consumed at the end use or uses.  On line software exists to easily calculate these natural losses based on the size of the piping, bends, and fittings encountered as the compressed air travels through the pipe.   Pipe size should be large enough to minimize pressure loss.  Hence planning for the proper size of piping should be done in advance by recognizing and accounting for all uses.  If something does not work when attached to a compressed air line, the first thing you need to check is the air consumption of the product against the line size.

Unintended loss occurs when you add to the air line, a set of fittings that are not designed for the intended flow and even a small diameter hose to a large airline.  That small hose and undersize fittings would be like trying to push and elephant through a straw.  The pressure drop can be quite high.  It has become quite fashionable to use easily connect plastic hose and fittings and use whatever might be readily available in manufacturing operation.  It is not unusual to see 8 mm hose connected from a 1″ air line to a product using a lot of compressed air, without realizing the large pressure loss in the hose.   The simple solution would be larger hose and accompanying fittings.

So in a pneumatically operated device is not operating as it should, the first thing that should be checked is “pressure drop”.

Lottery Ticket Quality Control with an Air Knife

Unusual applications for compressed air are always fun. One such unusual application was at a facility printing lottery tickets. Printing lottery tickets is much like printing money as they need to be controlled to a high quality to prevent counterfeiting. This also applies to major event tickets such as football, soccer, and baseball games.

In this application, the lottery tickets were printed with UV Ink, and the UV lighting would “set” the ink. But the ink was still not drying fast enough, and the print quality was adversely affected. They placed a small compressed air-operated air knife operating at low pressure (of around 30 PSIG), so it consumed very little energy. This was enough to provide the cooling effect to help set the ink and get a “perfect” lottery ticket.

So the next time you get a lottery ticket, you may wonder if they used an air knife..

Lottery Ticket Quality Control with an Air Knife

In steel sheet production or other metal sheet production, which is better to use for blow-off? – a series of many small compressed air operated flat jet nozzles or, one or more long compressed air operated air knives? In reality both have been used. Flat jet nozzles, being smaller, will provide a greater blow off force normally. However, air knives can have their force increased by increasing the air gap in the air knife and this often provides enough force for the same application, and indeed have been proven to do so. For this kind of application it means the addition of usually one or more shims to increase the gap.

The factors to consider are as follows:

Cost of Installation and the units: Multiple flat jet nozzles will usually cost more to use and install than one or a few long air knives.

Noise: A “good” air knife may be a little less noisy, even with multiple shims to make the gap bigger. But that depends on the number of shims used in the air knife and flat jet nozzles themselves.

Air Consumption: Depending on the set gap used in the air knives, overall air consumption could be less. This is something that can easily be calculated and determined.

Damage risk: If an air knife is damaged the cost to replace will be more than the cost of replacing a singles or even a few flat jet nozzles. If the risk of damage and replacement is high it skews the decision to flat jet nozzles. If the risk is low, then air knives would be a better choice.

Weighing the importance of these factors in any given situation will lead to the optimum choice for the particular location.

Compressed Air Flow Amplifiers and Back Pressure Issues.

Compressed air flow amplifiers (also called air movers) operate using something called the Coanda effect to convert pressure to flow with minimal energy loss. The result is high flow and less noise when used for blow off or cooling applications. However, often air amplifiers are also used for collecting and venting and/or conveying of fumes and light material.  Example are venting a tank, or even rooms because they move large volumes of air or gas.

A recent inquiry received requires a flow of 300 SCFM into a large tube of about 3 inches outside diameter. If for example a 2” air amplifier is fitted at one end, it can blow into that tube. Depending on the length of that tube there will be a back pressure.

A properly designed 2” air amplifier will amplify flow at its exit about 15 times and still maintain a good velocity to carry it into the tube. For example, whatever the compressed air use is, 15 times that will come out at the air exit. However, that “amplification” is in free space. When you add the tube to the amplified air outlet the back pressure will reduce that amplification to around 10 times for a tube about 3 meters long.  If, the tube is longer, has bends, or other internal restrictions (like a rough surface), then even more of a reduction occurs in air flow amplification.

Compressed Air Flow Amplifiers and Back Pressure Issues.

Back pressure concerns can be offset by using larger diameter pipe, tube or hose connected to the amplifier outlet and minimizing bends and other possible restrictions.  Another method to reduce back pressure, especially if the desire is to convey a greater distance is to install in-line a compressed air venturi unit. Air amplifiers boost volume, but venturis boost vacuum. Installing them in line extends the distance you can convey and reduces the back pressure.

Regardless of the venting or conveying application, back pressure should be a consideration when utilizing compressed air operated air amplifiers.

Compressed Air Flow Amplifiers and Back Pressure Issues.

This article is borrowed from a blog by the Marshall Institute at www.marshallinstitute.com

Teaching the Millenials a sound reliability strategy early in their career (the Matures, Baby Boomers and Gen Xers too) can be the critical component of a strong manufacturing strategy.

Millenials have been categorized as seeing the world as a union of people and countries connected electronically and technologically 365 days a year, 24 hours a day, 7 days a week; spending a lot of time interacting with social media and using more than one medium at a time, with parents that catered to their needs more than the rest of us. Some see them as most times arrogant but, they may actually be the most productive, innovative generation in history (Sujansky, 2009).  What in the world does this have to do with reliability? – a lot. Building a powerful brand comes with a strong reliability strategy. Every organization, no matter what it may be manufacturing, requires a powerful and strong reliability strategy lined up with its corporate strategy. In today’s climate this includes being connected and collaborating 365 days a year, 24 hours a day, 7 days a week; spending a lot of time interacting with social media and using more than one medium at a time not only with the corporate strategy but with people, processes, programs, and performance beyond internal and external boundaries. Reliability has evolved from a reactive, “keep the failures quiet,” enviroment brought on by pressures to meet production/manufacturing targets to the promotion and use of:

• Effective Communications
• Best practices approach
• Modern diagnostic tools
• Responsiveness

Maintenance and Millennials as a strategic tool are as relevant as understanding chronic problems with equipment and a competitive edge. While the Millennials may not understand the root cause of many failures, they can be a modern diagnostic tool at your fingertips to eliminate common root causes or find the counterpart of an outdated spare part.

For example, I was recently working with a group of Millennials. We were talking about communication styles between 20 something’s and “older” people and age discrimination against the Millennials. One thing that came out is how these Millennials have an app for everything. The short of the story is an intern was tasked to observe some surveying being conducted by a construction company and after about 20 minutes watching them scramble to calibrate some equipment he stopped them and said “hey, I have an app for that” they stopped, let him download it, and in the end he saved them a few thousand dollars in prep time over the summer.

Don’t have a millennial in your department? Not a problem. Millenials’ attitude can be found in all the four of the generations and have been but more so with the Boomers. According to Sujansky’s, Keeping the Millennial’s, the relationship with technology is shared – the difference is the platform. Boomers are post WWII technology, While  Millennials are post computer technology. Though their platforms for doing so are generations apart, both have an affinity for putting together technology to practice and the understanding of connectivity, collaboration and responsiveness is shared.

(Many thanks to the Marshall Institute for this article)

Nex Flow Distributor Event Pattaya Thailand 2017

Nex Flow Distributor event attendees were (in no particular order) from Canada, USA, Mexico, China, Taiwan, South Korea, Saudi Arabia, United Arab Emirates, India, Spain, Slovenia, Poland, Germany, Finland, Turkey, Philippines, Indonesia, Malaysia, Thailand, Australia, and South Africa.

It was a lot of work but also a lot of fun! Many thanks to all who were able to attend! It is a great group and an excellent team!

A happy person is a productive person but working in an environment where you sweat all day is not fun.

Even in the winter time in cold countries it can be very hot and uncomfortable working in factories such as steel mills and paper mills around certain heat generating machines.  One way to cool down is to use fans but electric cables could be a hazard to potentially trip over and fans can be bulky and take up a lot of space, plus difficult to move around.  Also, they do not blow cool air as the fan motor can actually heat up the hot air a bit more.

One alternative is a portable compressed air operated “Air Mover” or “Air Amplifier” that can be carried around and plugged into a nearby compressed air line.  They are more rugged and durable than a fan, more compact, and produce cooler air as the compressed air goes from high pressure to atmospheric pressure thereby cooling personnel better creating a more comfortable work environment and a more happy and productive individual.

Something to consider…….

Cameras are used extensively in production for monitoring to insure quality and are often exposed to hot and harsh environments and may require additional cooling.

The most common way to cool an industrial camera in very hot environments is to enclose it in a housing and then cool the housing with either compressed air alone, water, or using vortex tube cooling.

As the camera is in a hot environment, if compressed air is used, it will most likely be warm so a significant amount is required adding to energy cost.

Water will cool very well.  The housing will most likely have a cooling “jacket” where water is passed through.  But the space and cooling supply lines are relatively small, so unless the water is well treated and clean, the system can by highly subject to scale buildup and dirt and can clog risking downtime and increased maintenance costs.

Vortex tube technology which creates cold air from compressed air is a significant improvement in cooling over the two options above in that these units produce cold air which cools the camera.  It does not have the scale issues of water and you will use much less compressed air because you will be applying cold compressed air significantly reducing energy costs.

The point of use filter is a major center which maintenance is important in a compressed air line.

An area of major importance is point of use filtration in compressed air lines.   This simply means that a filter (should be) used in font of an air tool, pneumatically operated machine, an air nozzle, a vortex tube, and air knife, etc. is key to maintain efficient operation.

Dirt or moisture buildup in an airline can cause clogging, inefficient operations or even damage to any equipment.  Filtration upstream is not adequate as condensation can still occur in airlines downstream and dirt in airlines from corrosion can collect in piping downstream and enter the air tool, machine or nozzle as  result if no point of use.  Filters with replaceable filter elements to remove dirt and moisture (usually sized in the micron size and capacity it can remove) are common.   There is also usually two filters- one o remove moisture and the other t remove dirt.

They typically have automatic drains which work on pressure difference or with a float that removes the collected moisture, oil and dirt.  If they themselves become damaged or clogged due to dirt, then this contamination will get carried forward into the end use device or machine.   Designs which can limit contamination that can effect the drain performance and should be considered a major factor in deciding on a quality filter.

Another problem is the replaceable filter element itself in a filter. It will eventually get dirty and need to be changed.  Without replacement the contaminates get carried past or becomes so clogged nothing downstream works.  In very problematic air lines this makes filters a high maintenance item requiring frequent servicing.  An efficient separator type design with no filter element is available on the market that can address this problem of moisture, dirt and oil with one unit making the filter virtually maintenance free as they do not use filter elements eliminating the need to service the filter.  If the automatic drain is also of quality design even that issue can be greatly minimized.  These types of filters should be seriously considered especially in facilities with major water/oil issues.  Two things to look out for with these devices is to be sure they meet the ISO 12500 and ISO 8573.1 standards for filters (see: http://www.airbestpractices.com/system-assessments/air-treatmentn2/air-quality-standards-iso-85731-iso12500 )and that they can be easily dismantled and cleaned should contamination ever build up inside them – just in case.  Nothing is worse than to have a filter you cannot take apart to clean.

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This video illustrates some of the things to keep in mind when using vortex tubes in industrial applications.

Video url : https://youtu.be/3OIjke1lcwo

Point of Use​ Filtration in Compressed Air

Compressed Air technology for blow off an cooling involves the use of air flow amplifying products in the form of air nozzles, air movers and air knives used in blow off, venturis for conveying, as well as vortex tube (cooling) technology. Virtually all of these products involve small openings for the compressed air to exit or in the case of vortex tubes, air spinning back and forth in the tube.

With air amplification products you can end up with clogged nozzles or uneven flow in the case of air knives. Venturis will not work as well due to blockages. Water or any moisture inside a vortex tube will freeze and stop the unit form performing temporarily until the ice thaws and the unit starts up again.

Point of Use​ Filtration in Compressed Air

So the cleaner and more dry the air supply like the better – at least to 10 micron filtration of water. If there is oil in the airline, oil removal down to at least 1 micron is preferable. You may think your air line is clean and dry because at the compressor you have all the equipment for removing moisture and dirt. The problem is even in the cleanest of compressed air systems, several things happen downstream to cause dirt and moisture issue:

1. rusting of the piping that carries the compressed air due to stagnant low spots where condensation can collect.

2. entrainment of moisture from the atmosphere into the system because of leaks or other equipment.

3. condensation when the temperature of the compressed air falls below the dew point

So while treatment of the air is very important upstream at the compressor, point of use filtration is still important.

Point of Use​ Filtration in Compressed Air

Nex Flow Air Products. We are here to help.

Easy Engineering

Easy Engineering is a continuation of a series of educational videos to explain special compressed air-operated items for blow-off and cooling, moving on to what they are made of, how they work, and how to use them.

A vortex tube is a unique device that takes compressed air and literally divides it into a hot and cold stream.   There is usually no practical use for the hot air stream. Still, spot cooling for the cold end has many practical applications because of the product’s compact nature and mounting flexibility.  The product uses no electricity and is lightweight.

Vortex tubes can be made of different materials, such as aluminum, brass, and stainless steel, but stainless steel is more popular as it stands up better in factory environments.  A vortex tube is a device used to produce cold air and is often installed in hot areas.  Therefore, it is a better material to use in a hot, often dirty corrosive environment.

There is sometimes a misconception that the colder the cold temperature from the vortex tube, the greater the cooling effect.  That is incorrect.  As the vortex tube operates by dividing the incoming compressed air into two streams, it is important to recognize that the cold air temperature drop and the flow are interdependent.

You will have less cold end flow if you want a colder temperature at the cold end.   If you need more flow, the temperature drop at the cold end will not be as high.   The video explains this in more detail.

A piece inside the vortex tube called the generator controls the overall flow of air utilized.  The more compressed air consumed, the more the cooling effect.   There are also different types of generators.  One type restricts the flow on the cold end so that the cold end temperature is always very low.

Orientation of the vortex tube does not affect the outlet flow or temperatures produced, giving it flexibility for installation. Apart from spot cooling applications, they can also be used effectively to cool enclosures.

A vortex tube is an interesting device that takes compressed air and divides it into a hot and cold stream. Various theories try to explain why it works but there is no definitive answer. Their primary uses are for “spot” cooling and “enclosure” cooling. Despite their many advantages (compact, no maintenance, simple, rugged, portable), they are energy intensive so they do have a practical application limit.

Apart from special applications in the natural gas industry, vortex tubes are operated with compressed air. Compressed air itself is a green technology – it is the very air breathe, so the thought of using it to air condition a home is a concept some people imagine.

The problem is the size of area to cool. It would take a 40 HP air compressor to provide 10000 BTU/hr of cooling. That would handle one reasonable size room. So if you have several rooms (say 4) you would need at least a 150 HP air compressor. That in itself is a heavy cost just for the air compressor, then a separate room for the air compressor and of course the energy cost of running that air compressor. But if one day that air compressor can be solar powered, then – if you are willing to have a separate room for the air compressor, preferably sound proofed, then – maybe then – you can have an environmentally friendly, no chemicals, no maintenance air conditioning system based on vortex tubes in your home. Just the routine maintenance of the compressor is needed. But a sound proof room for your huge compressor??? Probably not very practical.

OTHER ARTCLES ON VORTEX TUBES:

Why Vortex Tube Panel Coolers are getting used more for Cooling Electrical Panels

Air Conditioner in Your Hand – Carbon Footprint Free

Impact of Kigali Agreement in Montreal Protocol in Industrial Cooling Applications

USING A RELIABLE VORTEX AIR CONDITIONER AS A BACKUP UNIT

A vortex air conditioner like a Nex Flow Panel Cooler is probably the most reliable type of system you can use in air conditioning control panels as it operates only using compressed air. They offer many advantages as explained in ths previous Linked In article:

But in some environments the cost of the compressed air may outweigh other costs and traditional air conditioners may be more economical to use. But since control panels create a “downtime cost” if overheating due to air conditioner failure, it can be worthwhile to install a vortex air conditioner as a low cost “backup” unit to avoid costly shutdowns.

As a backup however it is important that the control panel is relatively sealed to avoid the entrainment of hotter and more moist outside air. A thermostats and solenoid valve can easily and automatically turn the unit on should the main air conditioner fail. Once the ill-fated electrical air conditioner is repaired and running, the thermostat control will shut down the vortex system which will remain in standby mode until needed again.

A simple, low cost way to add security to any control panel that requires air conditioning to maintain secure and on going factory operations.

In choosing a company to deal with, you should look at the values that drive them.

Company values are the guiding principles and fundamental beliefs that help us function together as a team and work toward a common business goal. These values are essential to maintain our business and customer relationships and continue our company growth.

The first is dependability.   While sometimes we may mess up for one reason or another, we persevere to have a positive reputation for dependability.   To do this, we have adequate stock as many of our products are required for immediate use.

We keep track of supply chain issues and adjust inventory as best we can to ensure an adequate stock.  When orders are placed, we attempt to ship the same day or the next day and maintain good relationships with courier contacts to address problems that may occur and any lost shipments.  Should an error occur at our end in shipment, whether a missing item or anything else, we correct it.

While we attempt to take every call as it comes in, we attempt to call back as quickly as possible and address any email promptly.   We recognize the importance of every customer.   The dependability of our products is also essential.

Quality control is important, and we endeavor to make the best in our field with the highest quality.  For example, our aluminum products are anodized, while others in our industry do not.    There is a great deal of knowledge at Nex Flow in applying our technology which is essential to address the customer’s application most economically.

The second is safety.   This is not only maintaining safety in the workplace, but it is also producing products safe to use.  Our blow-off products meet OSHA and similar international noise and dead-end compressed air pressure standards.   The products are manufactured so they are safe to install and use by the customer.

The third is innovation.    While some in our industry copy each other, Nex Flow innovates.  We have several patents to our name.  Research and development are ongoing, with partnerships maintained with local educational institutions.   The goal is to improve what we have and develop new and improved products for blow-off, cooling, conveying, and other specialized compressed air applications.

 

Filters are an important component in any compressed air system.

Clean, dry, and even oil free compressed air and gas is a basic need for many industries. In some applications even a drop of unwanted oil or dirt can cause a malfunction. Oil can cause seals in pneumatic valves and cylinders to swell, resulting in sluggish operation and even seizure of moving parts. Compressed air used for blow-off applications needs to be clean and dry to prevent clogging in air nozzles and other blow-off product effecting production. These filters should be installed near the point of use of the particular compressed air application.

Contaminates in a compressed air system that can impair your process:

Solid particles come from ambient air contaminants like dust and also from rusted and oxidized pipework. These particles cause pneumatic equipment to malfunction, cause instrument and control failures, and contaminate end products especially if used as blow off air. Many pneumatic valves and cylinders contain small orifices that can easily get plugged with contamination.

Condensed water droplets come from the humidity in ambient air and condensation as compressed air cools and drops below the dew point. Water will oxidize the pipework and other pneumatic equipment and can damage the inside of pipes and other pneumatic components. It can ruin paint finishes and end products, again especially if the air is blown onto the products.

Liquid oil and oil vapors are introduced by compressor lubricants and by hydrocarbon vapors present in the ambient air. This is necessary for some pneumatic equipment but can be a problem for others and requires removal. Oil-free compressed air is particularly important in food and pharmaceutical processes. Oil particles should be removed when utilizing compressed air for blow -off.

Pneumatic filters of the traditional membrane type should be sized to handle the flow required. Sizing them two times higher than the rated flow will reduce pressure drop which saves energy and makes the filter elements last longer reducing maintenance. A differential pressure gauge across the filter will allow you to monitor the dirt buildup and change the elements when the pressure differential is high (usually at 10 psig). They should be equipment with automatic drains to remove the contaminants collected. Some membrane type filters are designed to remove dirt and water, and some to remove oil which is dealt with at smaller micron levels.

There is a new type of filter like the Nex Flow Super Separator that does not utilize a filter element. It operates using multi chamber spinning action to remove the contaminants, These systems are gaining acceptance and can filter to 1 micron and remove over 99.9 percent of the contaminants. If micron size is still important then a membrane filter should still be used after the Super Separator but in this case the membrane elements my rarely need to be changed. As with membrane filters, these Super Separators should have an automatic drain. because they do not have a filter element collecting dirt or liquid, there is no buildup of pressure drop over time.

Regardless of which type of filtration is used, it remains important to have filtration at point of use of the compressed air.

IMPORTANT GUIDELINES IN USING COMPRESSED AIR

1. Hoses and lines should be rated to meet the maximum operating pressure of the equipment – avoid using weak plastic tubing in open factory environment as they can split and cause leaks and possibly injury. Use properly rated hose or piping.

2. Wear proper Personal Protective Equipment as follows:

Safety glasses with side shields and a face shield if needed depending on the job at being performed.
Hearing protection if exhaust noise or impact noise is high as even short term exposure to loud noises can be damaging.
Respiratory protection, depending on the material(s) being worked with.
Note that normal work clothing is not protection against compressed air
If you must clean with compressed air, do not use air that is set above 30 PSI or utilize air amplification nozzles with a dead end pressure of no more than 30 PSI. (See:
You must also have effective chip guarding and proper PPE (OSHA standard 1910.242(b))
NEVER USE COMPRESSED AIR TO CLEAN CLOTHING OR HAIR!
NEVER POINT COMPRESSED AIR AT YOURSELF OR ANOTHER PERSON!

Anodizing is an environmentally safe electrochemical process that converts the aluminum metal surface into a porous aluminum oxide, ultimately creating an end product whose finish is more durable and weather-resistant.

Aluminum anodizing enhances the characteristics of aluminum in several ways:

Durability: anodized aluminum is more resistant to wear from normal handling and usage.
Finishing: more aesthetically pleasing finish, either clear or color
Corrosion resistance: increases the corrosion resistivity of the surface as it prevents further oxidization.
Lasting Color: a color finish added to anodized aluminum is more enduring
Strength: The anodized aluminum surface is harder than pure aluminum.
In particularly harsh environments, non-anodized aluminum can look pretty bad after even a year of operation such as the air amplifier shown in the picture above. While many aluminum air amplification products such as air knives and amplifiers and even air nozzles are not anodized by some manufacturers, Nex Flow Air Products does anodize to provide a superior product, often at a lower cost to avoid the oxidation as shown in the picture above.

Imagine a factory environment – maybe a fertilizer plant or a chemical production facility with electrical and electronic cabinets that need to be kept clean. Not only does the maintenance cost of maintaining the air conditioning systems become quite high, but they become very critical to protect the sensitive controls inside. The air conditioners themselves also are very costly as they need to be made in stainless steel for certain environments. For example, fertilizer production requires 316 stainless.

This is the perfect environment where vortex tube operated air conditioners excel. They use only compressed air to operate but the increased energy costs are more than offset by the near zero-maintenance of these devices in difficult surroundings. They have zero condensate, are not subject to vibration damage, have no chemicals to operate, no filters to change and slightly pressurize a control cabinet to keep outside air out protecting the controls inside. They can be supplied in 304 stainless or 316 stainless and even 316L stainless for pharmaceutical applications.

One of our customers made a very nice setup to dry extruded pipe using Ring Blade Air Wipes manufactured by Nex Flow Air Products Corp. Very easy to switch out one Air Wipe diameter with another size, as the picture shows to clean and dry different diameters of pipe.

Nex Flow Ring Blade air wipes are an efficient way to clean and dry extruded materials.   The air wipes utilize the Coanda effect to entrain along with the compressed air used to amplify airflow (converting energy lost as pressure drops and noise into useful energy)  to impinge the extruded part that is passed through the unit.

The air exiting the 360 circular ring from the Ring Vac exists at a 30-degree angle and concentrates the blow-off energy to the part.   This circular 360-degree ring consists of two half-circles mated together to make the full circle.   As it is two pieces connected together, the unit can be opened to allow any bubble or material jam from the extruded art to be passed through during the extrusion process.

Due to the high efficiency and concentrated flow, very often, a smaller number of Ring Blade air wipes are required for an application when compared to existing old-style air wipes.   Where in the past you needed three, you can often only need two Ring blade air wipes.

It is good practice to have the internal diameter close to but not equal to the largest outside dimension of the extruded part. This is because the airflow fans out the further you are from the air wipe.  In this way, you get maximum point force for blow-off.    This is why you have several different sizes of Ring blade air wipes set up to interchange easily for different diameters of the pipe being produced.

The video shows cylindrical pipe, but the Ring blade air wipes are also effective on odd shapes. They are used in applications such as extruded window profiles and EPDM rubber trim extruded for the automotive industry.   Highly efficient in performance, energy, and productivity for many extrusion applications.

 

 

Variable Frequency Drives describe equipment used to control the speed of machinery. Many industrial processes such as assembly lines must operate at different speeds for different products. Where process conditions demand adjustment of flow from a pump or fan, varying the speed of the drive may save energy compared with other techniques for flow control. There are two major problems however to account for with VFD’s.

1. When an application requires more current at a reduced speed, that means more heat and less cooling at the lower speeds. Most VFDs have limits to protect the VFD and consequently the motor. Too low a setting and there will be lot of trips. Too high a setting and there may be damage in high ambient temperatures. So cooling should be available at these low speeds.

2. Variable frequency drives come in various NEMA enclosures such a 1, 12, 3R and 4. The heat sinks for the transistors may be internal or external. Those that are internal such as NEMA 1 or many smaller HP units (and some 3R) are usually vented and rely on airflow through the enclosures. Dusty locations can easily clog air filters, where included, or drag dust in on the microprocessor motherboard and power components, creating electronic problems and excess heat on the power components. Conductive dust can short out power and controls. Dust buildup on the fan blades and external heat sinks can cause excess heat and fan failures. Improper selection, application and/or maintenance can result in problems or premature OVERTEMP faults. Installing chassis mount or units inside improperly vented custom enclosures and/or outside locations exposed to sunlight aggravates this problem as well.

One solution to address these conditions are compressed air operated vortex tube cooling systems such as Panel Coolers made by Nex Flow Air Products Corp. These cooling systems require any open vents to be blocked preventing dirt and dust from entering the control panel. Vortex tube operated coolers also keep the panels are a slight positive pressure to keep out dirt and even moisture in high humidity environments. Vortex tube operated control panel coolers can be provided with a solenoid and thermostat to turn the compressed air supply on and off when needed to provide the cooling only when needed, such as at startup when speeds are normally lower and heat generated higher. Since the cooling is not required at the higher speeds the units can then be turned off automatically (on-off control). A bypass line across the solenoid valve can keep a tiny flow of compressed air into the control panel to keep it clean in a very dirty factory environment. Overall use of compressed air can actually be quite low so energy use is kept minimal. Other advantages with vortex tube coolers is virtually zero maintenance, their ruggedness and the fact they do not produce condensate which has to be taken care with standard air conditioning systems.

In some industrial casting and forging situations the items made need to be cooled quickly for handling purposes or for an on-going process such as marking or assembly, otherwise the processes cannot be completed properly or handling would not be safe or possible. Cooling can be done with fans but they can be too slow to cool. Similarly using water to cooler involves an extra step of drying, slowing the operation. So the next step would be the use of purely compressed air.

Compressed can be costly to use. Sometimes air nozzles are used and work well for small parts and surfaces but larger surfaces would be very inefficient and use a great deal of energy. In those cases the use of “larger” air amplifiers or air movers is the most efficient solution. They will cool much faster than fans (10% faster or more) which can provide tremendous production cost savings. Air amplifiers convert pressure to flow, minimizing energy losses and also lowering noise levels, a further improvement to the factory environment. Such larger air amplifiers are more efficient in energy use than smaller nozzles. The best sizes for cooling larger parts would be air amplifiers of 1-1/4″ to 2″ in opening size. Cooling a part 6 square inches in area for example would only require four units at relatively low cost in both product cost and energy use, reducing energy well over 50% compared to open compressed air by itself and even savings against smaller nozzles of up to 25%.

Apart from such production applications air amplifiers. in particular sizes in 2″, 4″ and 8″ are used in pulp and paper mills, mines, and even in foundries for cooling personnel due to their portability, and also used for venting as they move a large volume of air.

There is a big shift in thinking and therefore the way things are being done in industrial operations with the entry of more and more millennials coming into the workforce. What this means to promotion and reaching out and getting accepted by millennials is dramatic. For example is this story:

One of our Nex Flow representatives wanted to go out of the office and purchase some office supplies. The reasoning was this: he gets out of the office, gets to see what is new, and can shop around to see what might be on sale and see what else is needed. But before he could get out of his desk, his assistant – a millennial had ordered everything on line and the material was delivered the same day. The assistance literally could not see the point of wasting time leaving the office, spending money of gasoline polluting the atmosphere, and looking around when all this could be done on line – it would be “inefficient”.

The new industrial customer or prospect looks to technology to procure In surveying many of our sales people the first thing millennial purchasing personnel universal asked was: do you have a web site? And can the product be purchased on line? This means that you better have a web site, it better be friendly and easy to use, and if questions arise during the purchasing process, that questions can be addressed quickly – perhaps with a 24 chat line, or a Q & A section on your product(s). It is known that millennials keep a close network of “connections” where they can ask about your products- so the image you have on line also becomes important. Just throwing up a web site and waiting for orders will no longer work – it has to be easy to use, quick to inform and user friendly.

This “overall efficiency thinking” should may carry throughout the entre industrial process. It is not just improving for example, energy efficiency, but also work environment (noise levels), maintenance issues, and even benefits to the world outside of the factory. Therefore your corporate values become important and needs to be shown.

It is no longer just solving a particular problem, as that can sometimes give rise to new problems. It is a change of focused thinking to a more overall, inclusive approach – an overall benefit. Millennials do think and act differently. Boomers have a difficulty understanding how two millenials standing across form each other in the same room will text each other instead of talking to each other but if one puts themselves into their thinking it suddenly makes more sense. It’s all about efficiency – but not just at a small level either – it can be at many levels.

Something to ponder…..

Late October, 2016 there was a landmark agreement among 170 countries to set firm dates for the curbing the use of HCFC’s in air conditioning systems with penalties for non-compliance. Developed countries must reduce their use of HFCs by 10 percent by 2019 from 2011-2013 levels, and then by 85 percent by 2036. A second group of developing countries, including China and African nations, are committed to launching the transition in 2024. A reduction of 10 percent compared with 2020-2022 levels should be achieved by 2029, to be extended to 80 percent by 2045. A third group of developing countries, which include India, Pakistan, Iran, Iraq and Arab Gulf states, must begin the process in 2028 and reduce emissions by 10 percent by 2032 from 2024-2026 levels, and then by 85 percent by 20

Replacements have been developed but they remain controversial for several reasons: higher cost of replacement material, possible flammability issues especially in the use of air conditioners in automobiles where one replacement material is now used. With safety in the workplace also increasingly important, alternative technologies may have to be considered for cooling applications.

For very large applications alternate systems may create a move back to the use of water cooling (chiller systems) to avoid the increased costs to update air conditioning systems. Not only are the refrigerants more costly but because they are inherently more volatile, materials used in the equipment may have to be updated as well.

For smaller applications such as the cooling of electrical and electronic control panels, vortex tube technology becomes more economical. Vortex tube cooling systems utilize compressed air and create a cold stream of air which is used for cooling. (see for example www.nexflow.com/172-chttpsabinet-enclosure-coolers ) While the use of energy is higher, they become economical when weighed against the cost of maintenance (replacement filters, cleaning, condensate removal, etc.) of traditional air conditioning systems especially in very hot, humid and dirty environments due to their near maintenance free nature. They are now used as well where intermittent cooling is required such as with variable frequency drives where overall energy use is low. As the Kigali Agreement takes effect, these systems will become more and more economical to use not only from the increased costs of air conditioners but also as maintenance personnel become more costly and harder to get – a double hit. Maintenance free will become much more important along with environmental responsibility.

How to have Control Panel Air Conditioning meet the requirements of the Kigali Agreement

On Oct 15, 2016 countries around the world signed on to the Kigali Agreement, an amendment to the Montreal Protocol, which hopes to reduce the use of hydrofluorocarbons (HFCs) significantly. The deal promises the largest temperature reduction ever in history, by limiting the use of greenhouse gases. The Kigali Agreement will see richer countries cut back their HFC use from the year 2019. Developing countries and other struggling economies will have their own delayed timeframes and benchmarks to adhere to.

This three-path agreement is expected to reduce global warming by half-a-degree centigrade and experts are optimistic the accord will remove the equivalent of about 70 billion tonnes of carbon dioxide from the atmosphere by 2050. In factories around the world air conditioners are used to cool electrical and electronic control panels. These can be replaced with vortex tube operated systems. A vortex tube uses only compressed air which is a relatively green technology as the source of power to create a cold stream of air at one end used for air conditioning. Other advantages include near zero maintenance, pressurizing the panels to keep out moisture and dirt, long and durable equipment life as no moving parts, low cost designs, and no condensate to dispose of which is another environmental issue and cost.

While not practical for large applications like your home or building air conditioning, the applications for small enclosures can make the switch to a climate friendly technology simple, easy and in many cases more economical when all factors are considered, especially as changes to traditional air conditioning systems will create added costs in the future.

Compressed air is viewed as a costly method for blow off and cooling applications and some look to electric motor driven blowers as a replacement. This is a reasonable with a focus for energy saving being a major factor. However, the cost of changing to a blower system is NOT always the most economical solution. What should be considered are he following six (6) critical factors:

1. Will a blower system work as well as the compressed air system? You actual force and needed for the application needs to measured. This will determine what size, and even if, a blower can do the same job. If a compressed air system is replaced with a blower, and it is found to be less effective, it will slow down production and these losses will offset any energy savings. In fact, what usually happens is the blower system gets a supplemental compressed air blow off added back negating the anticipated energy savings. A car wash system can be effective with blowers because it is “slow”. But a production line with a more complex item to dry may require the power of the compressed air blow off.

2. What is the actual energy used? A company offering compressed air blow off tends to provide examples minimizing their overall cost against blower system and companies offering blower systems do the reverse – they provide examples maximizing compressed air cost against their blower systems. The answer is usually in between. In this case, the actual force needed for the application will determine what is best. For example, if the compressed air application only needs to be at 40 PSI to provide the force required, then the actual energy needed is much less than if the pressure has to be 80 PSI. In fact, it drops to about 50%! Also, compressed air systems can be cycled on and off instantly. A blower system cannot, otherwise you burn pout the motor. As a simple example, if the compressed air is only on 70% of the time, that is a reduction of 30% energy use. Both these considerations, when weighed against the use of a blower system can sometimes equate to actual energy use close to and even “less” than a blower system. Sometimes a blower system is combined with a heater which can also be a major source of energy use that needs to be considered. Like the blower itself, the heating coil is not cycled on and off, at least not quickly.

3. What about maintenance cost? As compressed air has many uses other than blow off applications, the maintenance cost will not likely change for the existing compressors. Compressed air blow off products themselves are essentially maintenance free. However, when you “add” a blower system you now have another machine to care for. This is a cost. Also, you typically do not have a central blower system – you have one per machine. That increases maintenance costs which need to be carefully evaluated. It is not uncommon to have increased maintenance costs more than offset any perceived energy savings. In a world with a shortage of qualified maintenance personnel, this is a serious consideration.

4. What about noise? Compressed air blow off technology exists to reduce exhaust noise to much lower levels than just open pipe or tubes and are increasingly utilized. But when you put in a blower, you now have to deal with increased noise – noise much louder than a compressed air blow off. This is detrimental to worker safety and can even affect labor relations if the factory environment gets “louder”.

5. What about space? Compressed air blow off products take up very little space. When you add a blower – you take of more space. This may or may not be a consideration.

6. Downtime Risk? Typically compressed air systems are off a central system and compressor, or series of compressors with backup. However, a blower would be “per machine” so if one blower goes down, that line is down. Reliability requirement should be seriously considered in the particular application.

In the real world, either system is best depending on the factors above as well as the particular goals of he company. Each system has their advantages and disadvantages but one is objectively better than the other depending on the particular application.

In cleaning statically charged products there are claims by some companies that static can be removed as far as 20 feet away. What they do NOT say is how fast. This can lead to disastrous applications in manufacturing applications. The fact is, the further you are away the longer it takes for a static removal device to remove the static.

In cleaning statically charged items, you add either a blower or a compressed air blow off unit to the anti static device. These items “push” ions created by a static device to the charged part. However, it will take longer to remove static simply because more of the ions recombine before arriving at the part the further you are away. That time can be many seconds or much more the greater the distance. In reality the “part” needed to be neutralized and cleaned may not be subjected to the static removal device for more than a second – and much less in fast moving production. The only way to compensate would be to use a more powerful static removing device.

Here are the general rules to consider in the cleaning of statically charged products…..

1. You cannot remove static charge from a statically charged item 10 or 20 feet away in a reasonable amount of time – period, even if combined with a compressed air blow off or blower. Static removal is time dependent.

2. Compressed air operated blow of products such as air knives or amplifiers work better farther away from the charged item than a blower. But the further away, a stronger static removal device is required.

3. The strength of the static removal device determines the rate of static removal. So the higher the static charge on the part and/or the faster it move, the stronger the static removal device should be.

So when you read wild claims of devices that can remove a static charge at ridiculous distances, be very cautious. If you have an issue cleaning statically charged items deal with a company that knows what they are doing and has a range of quality products to support you.

Both low pressure blowers and high pressure compressed air is used for blow-off and cooling applications. Much has been made of the higher energy cost in using compressed air over the last 15 to 20 years which all started when the cost of compressed air “leaks” came to light, putting added focus on compressed air cost. However, the choice between the two is not always so clear as there is far more than energy cost to consider.

1. Blowers have high purchase price which needs to be considered if a compressor already exists.
2. Blowers take up space and must be close to the application – so if space is an issue the compressed air option may be better
3. Unless a very high powered blower it will not dry nor cool as well as a compressed air blow off. Many times a blower is installed and then supplemented with compressed air simply because it does not dry or cool adequately cutting into perceived energy savings. Blowers rarely have the same blow off power of a compressed air blow off. Most likely you only need to use the compressed air blow off at lower pressure than line pressure. You can reduce the energy use of compressed air by over 60% if you use only need 30 psig for the application as an example. In addition, blowers cannot be cycled on and off. If the need for blow off is intermittent, the larger the gap between the time the compressed air blow off needs to work, to when it can be cycled off, it approaches the same level of energy use, and in some cases even less.
4. Blowers are noisy – a major safety issue that often exceed OSHA exposure levels which compressed air products to reduce noise for blow-of and cooling exist
5. Blowers have higher maintenance – filters changed every 1 to 3 months, belts replaced every 3 to 6 months, bearing replacements
6. Difficult environments affect choice. When environments are too cold, too humid or too hot, blower maintenance goes up to the extent it can me more than the energy cost of using compressed air.
Questions to ask yourself when considering which technology to use

Actual force needed for cooling or blow Compressed air blow off companies often minimize the energy cost they need and maximize the maintenance and capital costs of blowers unrealistically. Blower companies do the reverse – the stretch the energy cost used in compressed air by calculating costs at higher pressure than may be needed, not factoring in intermittent use, and minimizing the maintenance costs that may be incurred in using a blower. They also rarely mention the noise factor which is a major safety issue an the extra space the system can take up. In making the appropriate choice you need to ask the following:

1. Get an true Idea of maintenance cost on the blowers, repairs, replacement parts, and downtime cost of maintenance for the environment that it would be in. The more harsh the environment, the more it favors compressed air. If less harsh a blower.
2. Is noise an issue? If so, the compressed air is favored.
3. What is are you drying or cooling? How much force is really needed to do the job? Is the part(s) continuous or intermittent (which would allow cycling on-off if compressed air is used). If continuous, it favors a blower an if intermittent, it favors compressed air.
4. Do they have excess compressed air capacity? Obviously to use compressed air you would need to have the capacity.
As energy costs go down with green source coming into play, and maintenance costs rise due to lack of qualified personnel, and as factory noise issues take precedent, these factors will also have an influence into the proper choice to make favoring compressed air over the longer term.

Several companies manufacturer vortex tube operated air conditioners primarily for electrical and electronic enclosures. Some promote them as the solution to all applications when in fact that is not the case. There are many types of devices on the market for air conditioning control panels and all have their place. Vortex tube devices use compressed air to create cold air which is piped into a control panel for air conditioning. They do not electrics except for optional thermostat and solenoid valve systems to turn them on and off as required. This saves on compressed air cost. They create no condensate and actually keep the inside of a control panel at a slight positive pressure. This is ideal in very humid and/or dirty environments. They have near zero maintenance and are rugged to hold up under difficult environments including vibration. Their performance is dependent only on the temperature of the compressed air, so they can be more efficient in very hot end humid environments.

Taking the above into account they are most applicable for cooling control panels in the following situations:

1. Very dirty environments as they keep control panels clean, extending their life span. With no filters to replace, the added cost of compressed air is offset by the savings in replacement filter material and labor.

2. Where maintenance is difficult such as in remote areas, or difficult to reach areas in a factory, or when maintenance personnel are not easily available for servicing.

3. Very hot and humid areas due to their increased efficiency as the performance is dependent only on the compressed air temperature. In such environments Freon or other chemical operated units become less effective.

4. Where cooling requirements are intermittent such as with variable frequency drives where the heat is generated mostly during a machine startup. In this case compressed air cost is much less and since the units are maintenance free become more cost effective.

5. Smaller control panels and devices where they use very little compressed air and become very cost effective such as for bar code machines, laser markers, industrial cameras.

As energy costs go down with the advent of green technology, and as labor costs rise, such maintenance free systems will increase in use especially for these ideal applications.

With the advent of new technologies, manufacturing will be transitioning in ways that not even science fiction could foresee. Some trends to note…

1. New techniques such as 3D printing will eliminate the need for many products now produced in factories or transform how they are produced to stay competitive. New materials using nanotechnology are being developed.

2. Artificial intelligence will replace most factory workers, and we may even end up with factories where the only worker is one person managing the robots if “that” is even necessary.

3. Despite the “hanging on” of old thinking and still prevailing use of carbon-based energy, the trend is inevitable to greener sources, perhaps mainly ever-improving solar energy and all that it implies. Solar energy will continue to get lower in cost and more efficient using nanotechnology in producing energy and storage. It is possible, if not probable, that energy will only get “cheaper” in the long run. Even oil is now “cheap.” Fusion is feasible in 10 to 20 years, providing unlimited energy.

4. For factories where there are still people, even in all robot factories where people will occasionally enter for maintenance on the machines (maybe….), the factory environment will have to be more friendly. So the factory environment will have to be clean, safe, and quiet.

5. Energy-intensive but “safe” energy use methodologies will grow, such as compressed air, which is safe, easy to store, used on demand, and where compressed air operated products are sturdy, simple in design, relatively low or maintenance free, and long-lasting. Pneumatic-based production may become more prevalent in these robot factories. Compressed air used for cooling will be cost-effective as no carbon footprint, while energy-saving, sound-reducing blow products will make for a quiet operation with no maintenance.

While disruptive, a very different but exciting world awaits us all.

Why Vortex Tube Panel Coolers are getting used more for Cooling Electrical Panels

Vortex tubes create freezing air from compressed air and are used as air conditioners for cooing control panels – even cameras in hot environments. Main complaint against using vortex tube cooling units for air conditioning is the cost of compressed air but in fact, standard air conditioners keep rising in cost. As HCFC’s are eliminated, the choices for cooling media become high pressure carbon dioxide or dangerous ammonia and all have added costs – and they still leave a carbon footprint. Vortex tube units use only compressed air – “the very air you breathe”.

They are extremely reliable with no maintenance, not subject to vibration, last for years with nothing to break down, and keep control panels at a positive pressure to keep out moisture and dirt so harsh environments are ideally suited for their use. Regular air conditioners need filters replaced with increasing disposal costs. As energy sources become more green, and air compressors become more efficient, the cost of using and operating vortex tube panel coolers becomes more attractive compared to the rising costs of regular air conditioners, That is before even considering the cost of repair for air conditioners as available service personnel become more of a premium in the future. All these factors need to be considered. An essentially green technology, with no maintenance looks much more attractive when contrasted against all the factors involved in air conditioning.

Of the roughly 40 million Americans suffering from hearing loss, 10 million can be attributed to noise-induced hearing loss.

With extended exposure, decibel levels of 85 or more can lead to hearing loss. Exposure to impulse or continuous loud noise may cause a temporary hearing loss that disappears 16 to 48 hours later. Although the loss of hearing seems to disappear, research shows there may be residual long-term damage to your hearing.

Factory noise comes from many sources but one preventable source is an area often ignored – compressed air used for blow-off, cooling, cleaning, drying or part ejection. Despite technologies being available for many years to reduce the exhaust noise from these applications there is still a prevalence of “noisy” and unsafe open tubes and pipe being used.

The most effective noise reducing technology uses something called the coanda effect which minimizes energy loss to maintain the energy needed and reduce noise levels by as much as 10 dBA. They even reduce exhaust pressure to safety levels. Attempts made to replace compressed air blow off with blower supplied air reduce energy cost, but the resulting noise from blowers can cause more damage to hearing, offset energy cost saving due to increased maintenance and often not even work as well as a compressed air!!. This is the reason compressed air – “the air you breathe!” – is still so prevalent in use for blow off, cleaning, cooling and drying applications. Low cost technology is available to reduce noise reduced dramatically, with energy savings and enhanced safety.

Air Blade air knives from Nex Flow reduce noise levels dramatically in a blow off tunnel.

Imagine a more quiet factory environment!

Several options are available when addressing a blow-off, drying, cleaning, or cooling application.   The most costly operation is rows of open tubes or a pipe with holes.   While it is the lowest in cost to set up, the energy use could be more efficient with modern options rather than these methods.  While still in use, pipes with holes and rows of open tubes disappear over time.

With the advent of engineered air nozzles, jets, and air knives, these low-cost devices replace those older costly options.  But there is still the issue of choosing among these modern engineered blow-off options, which can be challenging.

The first decision is whether the application should utilize an engineered nozzle, another annular compressed air blow-off, or a flat nozzles system like a flat jet or air knife. For flat, relatively flat, or curved surfaces that require a uniform blow-off across an entire length or width, typically, the decision is to use a flat jet like the Nex Flow Air Edger flat jet or air knife like the Nex Flow X-stream Air Blade air knife.

Other videos and blogs discuss the reasons for using flat-type nozzle systems versus annular devices.   There are several things to consider if it’s a choice between a flat jet nozzle and an air knife.

If the application is for a relatively light blow-off, such as drying a product, the choice tends to be an air knife.  The advantages of an air knife are generally less energy consumption, lower noise levels, and a continuous, relatively even flow along the entire length.

Care should be taken that the air knife quality is there and the flow is relatively even along its length.    Not all providers produce quality air knives; even if they look similar, there can be significant differences in internal design that you do not always notice from the outside.

Air knives are usually made of aluminum or stainless steel.  Aluminum units should be anodized for factory environments. Some users’ biggest complaints about air knives are using plastic shims to maintain the air exit gaps in the devices.  Even with a relatively clean compressed air supply, plastic shims wear quickly.  Nex Flow only uses stainless steel shims.

Air knives are also one device to use as needed, rather than several smaller flat jets.  So it’s just more straightforward.

However, air knives do have an upper limit for force.   A row of flat jet nozzles will be necessary for applications requiring a more potent force.

The Nex Flow design uses flat jets and air knives with stainless steel shims.  But by their nature, greater gaps can be used with flat jet nozzles than with air knives to create a very powerful blow-off when required.   The jets are typically provided on manifolds of standard length requiring two to twelve jets.   Special manifolds have been made upon customer request.

There is one advantage with such manifold-mounted systems, which is flexible to change the flat jets to other blow-off devices and add swivels and extensions to the manifold, and then the flat jet for applications that may require it.   But in those situations, the air knives would most likely not even come to mind.